China Die Casting Mould Manufacturers

Selected Die-Casting Materials to Meet Diverse Performance Requirements

Targeting the requirements for part strength, weight, and corrosion resistance across different industries, four major categories of mainstream die-casting alloys are carefully selected

Material Type	Common Grades	Core Performance Parameters	Core Characteristics	Applicable Scenarios	Notes
Aluminum Alloy	ADC12, A380, A356	Density: 2.7g/cm³Melting Point: 600-680℃Tensile Strength: 200-300MPa Brinell Hardness: HB 80-100	Lightweight, high strength, good thermal conductivity, better corrosion resistance than zinc alloy, excellent fluidity, suitable for forming complex structures	Automotive engine brackets, laptop casings, home appliance compressor parts, 5G base station heat sinks	Accounts for over 70% of die-cast parts, currently the most widely used die-casting material
Zinc Alloy	Zamak 3, Zamak 5, Zamak 7	Density: 6.6-6.8g/cm³Melting Point: 420-450℃Tensile Strength: 180-250MPaBrinell Hardness: HB 60-80	Low melting point (lower melting cost), excellent fluidity, easy to form thin-walled small parts, recyclability rate ≥95%	Toy parts, door lock panels, hardware accessories (faucet handles), small load-bearing parts for home appliances	Obvious cost advantage, suitable for small-batch and multi-style part production
Magnesium Alloy	AZ91D, AM60B	Density: 1.8g/cm³Melting Point: 590-610℃Tensile Strength: 240-320MPaBrinell Hardness: HB 70-90	Lighter than aluminum alloy (weight reduction of about 33%), strong shock resistance, excellent electromagnetic shielding effect, fast heat dissipation	Mobile phone middle frames, lightweight parts for new energy vehicles (battery brackets), UAV fuselages, high-end electronic device casings	Higher cost than aluminum alloy, mostly used in scenarios with extremely high "lightweight" requirements
Copper Alloy	Brass C36000, Bronze C95400	Density: 8.5-8.9g/cm³ Melting Point: 1083-1100℃ Tensile Strength: 300-400MPa Brinell Hardness: HB 100-120	Excellent thermal/electrical conductivity (2-3 times that of aluminum alloy), high temperature resistance, high hardness, good wear resistance	Electrical connectors, heat sinks, precision valve parts, core components of plumbing equipment (faucet valve bodies)	High melting point (high die-casting difficulty), high cost, suitable for high-performance demand scenarios

Post-Die-Casting Processing

Die-cast parts require systematic post-processing to correct defects, improve precision, and enhance performance.

Preprocessing: Removing Redundant Structures

Precision Machining: Achieving High-Precision Features

Surface Treatment: Enhancing Performance and Appearance

Cleaning and Inspection: Ensuring Qualified Finished Products

Core Equipment Selection

Preprocessing: Removing Redundant Structures

Gate and Riser Removal

Function: Cut off the part’s feeding channel (gate) and shrinkage compensation structure (riser) to clear obstacles for subsequent processing.

Process: For small parts, use a "punch press + custom mold" for one-time cutting; for large parts, use a hydraulic cutting machine for precise cutting, and grind the transition surface after cutting.

Standard: No cracks or dents; dimensional error within ±0.2mm.
Flash and Burr Removal

Function: Remove excess metal (0.1-1mm thick) overflowing from the mold parting surface to avoid affecting assembly.
Methods:

-- Complex curved surfaces/small holes: Process with a pneumatic sander (Ra ≤ 3.2μm);

-- Batch small parts: Vibratory finishing (flash removal rate ≥ 95%);

-- High-precision parts: 6-axis robot + high-speed milling cutter (precision ±0.05mm).

Preprocessing: Removing Redundant Structures
For IT7-IT9 grade tolerances that cannot be met by die casting, key functional features are completed through CNC machining.

Hole Machining (Locating Holes, Assembly Holes)

Process: Drilling (select carbide/high-speed steel drill bits according to the material) → reaming for precision refinement.

Standard: Hole diameter tolerance ±0.015mm; hole spacing error ≤ 0.03mm.
Thread Machining (Connecting/Fastening Threads)

Process: Internal threads (drilling + machine taps, with 1-1.5 times the pitch allowance for blind holes); external threads (thread rolling/turning).

Standard: Thread precision 6H (internal)/6g (external); qualified through go-no-go gauge inspection.
Flat/Surface Milling (Sealing Surfaces, Contoured Surfaces)

Process: Flat surfaces processed with face mills (Ra ≤ 3.2μm); contoured surfaces processed with ball-end mills + 3/5-axis linkage (fit degree ≥ 98%).

Standard: Flatness ≤ 0.02mm/m; profile tolerance of contoured surfaces ≤ 0.05mm.

Surface Treatment: Enhancing Performance and Appearance

Processes are selected based on materials and requirements, balancing corrosion resistance, wear resistance, and aesthetics.

Material	Process	Application Scenarios	Core Advantages	Key Standards
Aluminum Alloy	Anodizing	Outdoor parts, heat sinks, medical equipment	High corrosion resistance (no rust in 240-500h salt spray), dyeable	Hardness ≥ 300HV; color uniformity ΔE ≤ 1.5
Aluminum Alloy	Painting	Home appliance casings, industrial shields	Low cost, custom multi-colors	Hardness ≥ 2H; adhesion Grade 1; no peeling after 24h water resistance test
Zinc Alloy	Electroplating	Automotive interiors, hardware accessories	Mirror effect, high wear resistance (no scratches after 500 rubs)	No corrosion in 48-96h salt spray; gloss ≥ 90GU
Zinc Alloy	Painting	General decorative parts	Simplified process, color adaptability	Special primer; adhesion Grade 0

Cleaning and Inspection: Ensuring Qualified Finished Products

Cleaning
Process: For ordinary parts: high-pressure spray cleaning + hot air drying; for precision hole parts: ultrasonic cleaning + vacuum drying.
Standard: No surface impurities; no blockage in precision holes.
Inspection
Appearance: No cracks or scratches (≤2mm); no sagging or color difference on the surface;
Dimension: Measured with calipers/micrometers/3D coordinate measuring machines;
Performance: Salt spray, hardness, and adhesion tests;
Internal: X-ray/ultrasonic inspection for key parts; defects ≤ 0.5mm.

Core Equipment Selection

Process	Recommended Equipment	Applicable Capacity	Core Configuration Requirements
Flash Removal	Deburring Machine (Fanuc)	500-2000 pieces/day	Force control sensor to prevent over-cutting
CNC Machining	Vertical Machining Center (Taiqun)	300-1000 pieces/day (per unit)	Spindle ≥15,000r/min; tool magazine ≥24 tools

Post Die Casting Processing

We adhere to the ISO 9001 Quality Management System and have established 8 core processes to ensure controllability in every link from order placement to delivery:

01

Requirement Communication & Scheme Design

Connect with customer requirements: Clarify part application, performance requirements (e.g., load-bearing capacity, temperature resistance), production volume (small batch: 100-500 pieces / large batch: 10,000+ pieces), and delivery cycle.

Issue a scheme: Include material recommendations, mold design drawings, and quotation. Proceed to the next step after confirmation with the customer.
02

Mold Development & Debugging

Mold manufacturing: Adopt H13 hot-work die steel, processed through CNC machining, EDM (Electrical Discharge Machining) forming, and polishing.

Mold trial & debugging: Produce samples in the first mold trial, inspect dimensional accuracy and surface quality, and adjust mold parameters until meeting standards.
03

Raw Material Pretreatment

Material inspection: Verify alloy composition (e.g., silicon and copper content in aluminum alloy ADC12) to ensure compliance with industry standards.

Metal melting: Put raw materials into the furnace, heat to the corresponding melting point (aluminum alloy: 600-680℃ / zinc alloy: 420-450℃), and remove impurities (e.g., adding slag remover).
04

Die Casting Formation

Mold clamping & locking: Apply clamping force after mold closure to prevent molten metal leakage.

High-pressure injection: Inject molten metal into the mold cavity at a speed of 0.5-50 m/s, and maintain pressure for 3-10 seconds until initial solidification.
05

Mold Opening, Part Removal & Deburring

Automatic part removal: Use a robotic arm to take out formed parts, avoiding deformation caused by manual operation.

Deburring: Remove part gates and flash using methods such as vibratory finishing and laser cutting to ensure smooth edges.
06

Post-Processing (as required)

Machining: Perform CNC drilling, tapping, and milling on high-precision holes and threads.

Surface treatment: Support anodizing (for aluminum alloys), electroplating (for zinc alloys), and painting to improve corrosion resistance and appearance texture.
07

Quality Inspection

Dimensional inspection: Use a coordinate measuring machine and calipers to inspect key dimensions, with a pass rate requirement of ≥99.5%.

Performance inspection: Conduct sampling tests for tensile strength and hardness (e.g., Brinell hardness HB 80-100 for aluminum alloys) to ensure compliance with application requirements.
08

Packaging & Delivery

Customized packaging: Select cartons or pallets based on part size; add foam cushioning for fragile parts.

Logistics & delivery: Cooperate with various logistics providers; support batch delivery for large-volume orders.

AAA MOULD 5 Core Advantages of Die Casting

In the manufacturing of precision metal parts, die casting has become the preferred process for numerous industries due to the following advantages:

Higher Efficiency, Suitable for Mass Production

The production cycle of a single part is only a few seconds to several minutes (e.g., 3 seconds per zinc alloy small part). A production line can achieve a daily output of over 10,000 pieces, far exceeding sand casting (several hours per part) and machining (long processing time per part).

High degree of automation: It can be equipped with automatic feeding, part picking, and inspection equipment to reduce manual intervention and minimize production errors.

Higher Precision, Reducing Subsequent Processing

Dimensional tolerance can reach ±0.05-0.1mm, and surface roughness is Ra 1.6-6.3μm. Most parts can be directly assembled without secondary machining.

Capable of forming complex structures: Such as thin walls (minimum 1mm), small holes (minimum φ1mm), threads, and reinforcing ribs. Multiple parts can be integrated into a single die-cast part, reducing assembly procedures.

Lower Cost, Obvious Cost-Effectiveness Advantage

High material utilization rate: Scrap and waste parts can be recycled and remelted (recovery rate ≥95%), reducing material waste.

Low labor cost: Automated production reduces labor demand. The larger the batch, the lower the unit cost (slightly higher cost for small batches, and significant advantages for large batches).

Wide Material Adaptability, Meeting Diverse Needs

Can process various non-ferrous metals such as aluminum alloy, zinc alloy, magnesium alloy, and copper alloy. The properties of different materials adapt to the needs of different industries (e.g., magnesium alloy for lightweight, zinc alloy for low cost).

Stable part performance: The die casting process is controllable, and the mechanical properties (e.g., strength, hardness) of finished products are uniform with small quality fluctuations.

Good Environmental Friendliness, Conforming to Green Production

Compared with sand casting, no sand mold waste is generated, reducing environmental pollution.

Furnaces use natural gas or electric heating, with lower energy consumption than traditional casting processes. Waste heat recovery can be realized in some links.

Why Choose Us?

Die Casting Customization: Our 6 Major Service Commitments

Higher Efficiency, Suitable for Mass Production

- Different from large die casting factories (which only accept large-batch orders), we support small-batch customization to meet customers’ needs for trial production and R&D. We also offer flexible production capacity adjustment for large-batch orders.

- Quick Response: We reply to demand inquiries within 12 hours, provide solution designs within 3 days, and prioritize urgent orders (e.g., delivering small-batch samples within 7 days).

Professional and Experienced Technical Team

- Our engineering team has over 10 years of experience, with in-depth knowledge of the properties of different materials and industry standards.
- Mold Development Capability: We independently design molds and can optimize part structures based on customers’ drawings (e.g., adding reinforcing ribs to enhance strength) to avoid potential issues in later production.

Strict Quality Control and Guaranteed After-Sales Service

- Full-Process Quality Inspection: From raw materials to finished products, each link has inspection records, and non-conforming products will never leave the factory.
- After-Sales Commitment: If parts have dimensional discrepancies or substandard performance due to our reasons, we will re-produce them for free, eliminating customers’ worries.

Transparent Pricing, No Hidden Costs

- Quotations include all costs such as materials, molds, processing, inspection, and packaging, with no additional hidden charges. Customers can enjoy tiered price discounts for large-batch orders.
- Cost Optimization Recommendations: We provide suggestions such as recommending more suitable materials and optimizing part structures to help customers reduce total costs.

Considerate Service with Full-Process Follow-Up

- Dedicated Account Manager: Provide one-on-one service from order confirmation to delivery, and timely feedback on production progress.
- Technical Support: After delivery, we offer advice on part installation and maintenance. If customers have subsequent modification needs (e.g., minor dimensional adjustments), we can respond quickly.

Advanced Equipment and Stable Production Capacity

- Equipped with cold-chamber die casting machines and hot-chamber die casting machines, suitable for parts of different sizes.
- Equipped with testing equipment such as 3D coordinate measuring machines and hardness testers to ensure stable quality and meet customers’ large-batch needs.

Applications of Die Casting in Various Industries

With the core advantages of mass-producing complex structural parts while balancing precision and cost control, the die casting process has become a key manufacturing technology supporting the high-quality development of multiple industries.

Automotive Industry

With the rapid development of the new energy vehicle (NEV) industry, the role of die casting technology in lightweight and integrated production has become increasingly prominent.

Power System Components Body and Electronic Components
3C Electronics Industry

In the 3C electronics (computer, communication, consumer electronics) field, the demand for miniaturization, precision, and lightweight of components is increasing.

Consumer Electronics Components Communication and Server Components
Home Appliance Industry

Home appliances have high requirements for component cost-effectiveness and durability. Die casting (including low-pressure die casting and differential pressure die casting),

White Goods Components Kitchen Appliance Components
Industrial Machinery Industry: A Key Field for Heavy-Duty Die Casting

Industrial machinery (including machine tools, construction machinery, and agricultural machinery) has high requirements for component strength, wear resistance, and impact resistance.

Machine Tool and Construction Machinery Components Agricultural Machinery Components
Medical Device Industry: A Special Field for Precision and Clean Die Casting

Medical devices have strict requirements for component precision, cleanliness, and biocompatibility.

Diagnostic Equipment Components

Frequently Asked Questions (FAQ)

What is the die casting process?

A metal forming process where molten metal is pressed into a mold cavity at high pressure and shaped after cooling. It is suitable for mass-producing complex components.

What are the common metal materials used in die casting?

Mainly aluminum alloy, zinc alloy, magnesium alloy, and cast iron. Among them, aluminum alloy is most widely used due to its lightweight and high cost-effectiveness.

What size of components can be made by die casting?

It can be customized for sizes ranging from small 3C electronic parts to large components such as rear floor panels of new energy vehicles and thick-walled parts of industrial machinery.

What precision can die-cast parts achieve?

The conventional dimensional accuracy can reach ±0.1mm, and precision die casting can further improve it to meet high-demand scenarios such as automotive and medical fields.

Is die casting suitable for mass production?

Yes. Once the mold is formed, it enables rapid and repeated production, significantly reducing the unit cost, making it suitable for large-batch orders.

Is die casting suitable for small-batch needs?

It is feasible but requires cost consideration. The unit price of small-batch orders will be higher after sharing the mold cost. If there are plans for mass production later, small-batch trial production in the early stage is more cost-effective.

What to do if there are defects on the surface of die-cast parts?

Defects can be improved through post-treatments such as polishing, spraying, and passivation. Meanwhile, obvious defects are avoided in advance through inspections during production.

Which industries can die casting be applied to?

It is mainly applied in industries such as automotive, 3C electronics, home appliances, industrial machinery, and medical equipment.

How to ensure the quality of die-cast parts?

Inspections such as X-ray flaw detection, dimensional testing, and pressure resistance testing are conducted during production to ensure compliance with industry standards.

What is needed to customize die-cast products?

You need to provide component drawings (including dimensions and material requirements), batch demand, and application scenarios to facilitate quick quotation and mold opening.

Basic Introduction to Die Casting

Selected Die-Casting Materials to Meet Diverse Performance Requirements

Post-Die-Casting Processing

Process: Drilling (select carbide/high-speed steel drill bits according to the material) → reaming for precision refinement.

Standard: Hole diameter tolerance ±0.015mm; hole spacing error ≤ 0.03mm.

Process: Internal threads (drilling + machine taps, with 1-1.5 times the pitch allowance for blind holes); external threads (thread rolling/turning).

Standard: Thread precision 6H (internal)/6g (external); qualified through go-no-go gauge inspection.

Process: Flat surfaces processed with face mills (Ra ≤ 3.2μm); contoured surfaces processed with ball-end mills + 3/5-axis linkage (fit degree ≥ 98%).

Standard: Flatness ≤ 0.02mm/m; profile tolerance of contoured surfaces ≤ 0.05mm.

Surface Treatment: Enhancing Performance and Appearance

Cleaning and Inspection: Ensuring Qualified Finished Products

Core Equipment Selection

Post Die Casting Processing

AAA MOULD 5 Core Advantages of Die Casting

Dimensional tolerance can reach ±0.05-0.1mm, and surface roughness is Ra 1.6-6.3μm. Most parts can be directly assembled without secondary machining.

Capable of forming complex structures: Such as thin walls (minimum 1mm), small holes (minimum φ1mm), threads, and reinforcing ribs. Multiple parts can be integrated into a single die-cast part, reducing assembly procedures.

High material utilization rate: Scrap and waste parts can be recycled and remelted (recovery rate ≥95%), reducing material waste.

Low labor cost: Automated production reduces labor demand. The larger the batch, the lower the unit cost (slightly higher cost for small batches, and significant advantages for large batches).

Can process various non-ferrous metals such as aluminum alloy, zinc alloy, magnesium alloy, and copper alloy. The properties of different materials adapt to the needs of different industries (e.g., magnesium alloy for lightweight, zinc alloy for low cost).

Stable part performance: The die casting process is controllable, and the mechanical properties (e.g., strength, hardness) of finished products are uniform with small quality fluctuations.

Compared with sand casting, no sand mold waste is generated, reducing environmental pollution.

Furnaces use natural gas or electric heating, with lower energy consumption than traditional casting processes. Waste heat recovery can be realized in some links.

Why Choose Us?

Applications of Die Casting in Various Industries

Frequently Asked Questions (FAQ)

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