System of high-pressure die casting of ultra-large aluminum castings

A die casting system comprising:

• a die mold including an interior surface defining a mold cavity having a predetermined shape of a casting;
• and
• at least one ingate in fluid connection with the mold cavity, wherein the at least one ingate is configured to direct a molten metal flow into the mold cavity to form the casting;
• wherein the predetermined shape of the casting includes a first casting feature having a first thickness (T1) and a second casting feature having a second thickness (T2);
• wherein the second thickness (T2) is greater than the first thickness (T1);
• wherein the interior surface further defines a feeding channel extending from the at least one ingate directly to the second casting feature for conveying a portion of the molten metal flow from the at least one ingate to the second casting feature;
• wherein the feeding channel is sized to contain a reservoir of molten metal configured to:
• feed the second casting feature to compensate for shrinkage of the second casting feature during a solidification stage of a casting process, and
• form a support rib.