Service Process

01 Product Development Evaluation

1. Material Selection Evaluation

Select suitable materials, such as zinc alloy or aluminium alloy, based on product use, strength requirements and weight requirements, and consider their mechanical properties, corrosion resistance and cost.

2. Product Structure Design Evaluation

Evaluate the product wall thickness, rib design, hole configuration and demoulding angle to ensure that the structure is suitable for die-casting and avoid deformation or defects.

3. Feasibility Assessment Of Die-Casting Process

Analyze gate location, metal fluidity, cooling method and possible defects (such as pores, cold shut or shrinkage cavities).

4. Mold Design And Manufacturing Evaluation

Confirm the mold structure, slider design, ejection method and cooling system to ensure stable production of the mold and increase the life of the mold.

5. Assessment Of Dimensional Tolerance And Quality Requirements

Confirm dimensional tolerances and quality standards based on product functional requirements, and plan appropriate inspection methods.

6. Post-Processing Needs Assessment

Evaluate whether the product requires machining, tapping, drilling or other post-processing to ensure that the product meets the usage requirements.

7. Surface Treatment Needs Assessment

Confirm whether the product requires surface treatment such as sandblasting, electroplating, painting or anodizing, and consider its impact on product quality.

8. Production Cost And Mass Production Feasibility Assessment

Comprehensively consider mold cost, production efficiency and product quantity to evaluate the feasibility of product mass production and overall cost-effectiveness.

02 Mold Design And Production

Mold design and production are the key core for products to move from concept to mass production, covering various technical fields such as plastic injection, die-casting and stamping.

Develop Mold
Professional Standard Process

Standard mold development process diagram

1.Drawing Design

Mold development step 1: drawing and design

2. Mold Material (Hitachi) SKD61

Mold development step 2: selecting Hitachi SKD61 mold steel

3.CNCRough Machining Of Mold Core By Milling Machine

Mold development step 3: rough CNC milling of the mold core

4. Heat Treatment

Mold development step 4: heat treatment

5.CNCMilling Machine Finishing

Mold development step 5: precision CNC milling

6. Electric Discharge Machining

Mold development step 6: electrical discharge machining

7.Wire Cutting Processing

Mold development step 7: wire cutting

8. Drilling Machine Processing

Mold development step 8: drilling

9. Mold Assembly

Mold development step 9: mold assembly

10. Trial Mold

Mold development step 10: mold trial

11.Send Sample

03 Die Casting

A. Three Elements Of Die Casting

Pressure

Ensures that liquid aluminium can fill complex thin-walled structures and squeeze to reduce pores.

Speed

The filling time is very short (usually within 0.1 seconds) and must be completed before the aluminium liquid solidifies.

Temperature

Contains the balance between the molten aluminium temperature (approximately 670°C) and the mold preheating temperature.

B. Six Steps Of Production

Step1. Spray

Spray release agent on the surface of the mold to cool down and prevent the aluminium liquid from sticking to the mold.

Step2. Mold Closing

High pressure closes the mold to prevent the aluminium liquid from splashing (flying material) during injection.

Step3. Give Soup

Pour a certain amount of aluminium liquid into the injection cylinder automatically or manually.

Step4. Injection

The injection head is pushed forward in two steps, first exhausting and then high-speed filling.

Step5. Cooling And Mold Opening

Wait for the aluminium part to solidify before opening the mold.

Step6. Eject

Use the ejector pin to push out the finished product, and then enter the deburring or machining process.

C. Challenges And Solutions Of Die Casting Technology

Although die casting is extremely efficient, there are also some inherent technical difficulties:

Porosity Problem (Porosity): High-Speed Filling Can Easily Entrap Air.

Countermeasures: Add Vacuum-Assisted Die Casting (Vacuum Die Casting) Or Optimize The Exhaust Channel And Overflow Well.

Shrinkage: The Volume Shrinks When The Aluminium Liquid Solidifies, Causing Internal Voids.

Countermeasures: Add vacuum-assisted die casting (Vacuum die casting) or optimize the exhaust channel and overflow well.

Cold Shut: The Temperature Is Too Low When The Two Aluminium Liquids Are Combined And The Fusion Is Poor.

Countermeasures: Increase The Mold Temperature Or Improve The Runner Design.

04 Secondary Processing

Aluminium alloy and zinc alloy die castings usually require secondary processing to achieve final dimensional accuracy, appearance and functional requirements.
The key points of secondary processing of die castings are summarized as follows:

A. Stability Of Finishing (Machining)

Although die castings have high molding accuracy, secondary cutting is still required for threads, deep holes or extremely small tolerances.

• Base positioning: The first key to secondary processing is the unification of positioning standards. The most stable feature points during die casting must be selected as the processing benchmark to avoid processing deviation due to demolding deformation.
• Hole processing: Die castings often have internal pores. If pores are encountered during drilling or tapping, it is easy to cause the tool to break or the thread strength to be insufficient.
• Cutting allowance control: Too much allowance will increase costs, while too little allowance may result in poor surface quality due to holes under the casting skin.

B. Adhesion Of Surface Treatment

The surface dense layer of die castings is very important.

• Deburring and grinding: Use vibration grinding or sandblasting to remove burrs and flash on the parting line, which is the basis for ensuring smooth subsequent painting.
• Effect of silicon content: Aluminium die-casting parts often contain high silicon, and direct anodizing will result in black and uneven color. It is usually recommended to use powder baking paint or electroplating instead.
• Impregnation treatment: If the product has airtight requirements (such as engine casing), the tiny pores need to be filled with impregnated resin to prevent leakage after secondary processing.

C.Deformation Control And Stress Release

The surface dense layer of die castings is very important.

• Heat treatment control: Die castings may release residual stress when heated during processing, resulting in dimensional deviations. Key parts sometimes require manual aging treatment to stabilize their dimensions before finishing.
• Thin-walled parts support: Die-casting parts have complex structures and often have thin-wall designs. When clamping CNC, specially designed clamps with supporting force are required to prevent clamping deformation.

05 Quality Inspection

Mold Body Acceptance

· Dimensional accuracy: Use the CMM three-dimensional measuring instrument to verify whether the mold cavity, mold core and key parts (such as sliders and ejector pin holes) comply with the 3D drawing tolerances.

· Material and hardness: Check the steel type (such as H13, NAK80) and the hardness after heat treatment (HRC value) to ensure that the mold life meets the design requirements.

· Surface treatment: Confirm the polishing level of the mold cavity, whether the texture (texture) is uniform, and whether there are scratches or rust spots.

· Cooling and exhaust: Check whether the cooling water channel is smooth, whether there is any risk of water leakage, and whether the depth of the exhaust groove is appropriate (too deep may cause burrs, and too shallow may cause air blockage).

Die-Casting Molding Inspection

· Appearance defects: Check for sink marks, weld lines, flash, jetting or bubbles.

· Mechanism assembly: Carry out physical assembly test to confirm whether the hook strength, gap (Gap) and flush (Flush) are within the allowable range.

· Weight stability: Continuously produce digital molds and detect weight deviations of single products, which reflects the balance of mold cavity filling and process stability.

- Inspection Of Key Processes -

IQC (Incoming Material Inspection)

Confirm steel and standard parts specifications.

IPQC (Process Inspection)

Measurement of the first piece and key dimensions after CNC processing.

FQC final quality inspection and acceptance

FQC (Final Inspection/Acceptance)

The acceptance report confirms that both the product and the mold movement are qualified before leaving the factory.

Quality inspection methods including air-leak and X-ray tests

Key Points Of Quality Inspection

Air Tightness Test (Water Leak Testing): For functional components, air tightness testing after secondary processing is a must.

Internal defect scanning: Key parts can be inspected through X-Ray To confirm whether there are shrinkage cavities to ensure that internal holes will not be exposed after processing.

06 Packaging/Shipping

Die-casting parts often have precision machined surfaces. The focus is on preventing collision and deformation of the finished die-casting products. We attach great importance to the packaging process so that the products can be delivered to customers perfectly during transportation.

We package the finished die-cast appearance parts in bags and customize paper partitions and cartons to avoid scratches and bruises caused by direct friction and collision between metal and metal. In order to prevent the die-casting product from deforming due to overlapping extrusion, we use a customized PET vacuum box for layered fixation. When shipping, the outer box should have a material label clearly indicating the date, name of the material, quantity, and the accompanying product inspection report.

We cooperate with professional transportation companies and pay special attention to handling with care when handling to prevent the goods from falling heavily and ensure that the goods are delivered completely.

Truck transporting packaged die-cast products