The Definition of Die Casting

The Core Value of Die Casting: From Two Aspects

We can understand it from two dimensions. Manufacturers (suppliers) and product users (demanders) : It is not merely "casting" itself, but a systematic engineering solution that has created an irreplaceable comprehensive advantage for modern manufacturing.

I. Core values for manufacturers (Suppliers) : Scale efficiency and cost advantage

1. Unparalleled production efficiency

· High-speed cycle: The production time for a single piece is measured in seconds, and the annual output of a single die-casting machine can reach hundreds of thousands or even millions of pieces.

· High automation: The entire process from smelting, injection molding to part picking and spraying is fully automated and integrated, achieving 7x24-hour continuous production and significantly reducing reliance on manual labor and costs.

2. Outstanding economy (under the premise of large volume

· Extremely low unit cost: Although the initial investment in the Die is huge, once it goes into mass production, its cost is spread over a vast number of parts, making the unit manufacturing cost extremely low.

· High material utilization rate: The gates, runner channels, and waste products generated can be 100% recycled and remelted, with minimal material loss.

· Reduce subsequent processing: The near-net forming capacity reduces a large number of secondary processing procedures such as cutting and grinding, saving equipment and working hours.

 2. Core values for the product and end users (demand side) : Performance and design freedom

1.Achieve a high degree of integration of complex functions

It can form parts with complex geometric shapes, thin walls, fine textures and internal structures in one go, integrate multiple components into a single die-cast part, reduce assembly processes, and enhance the overall structural strength and reliability of the product. This is its most core engineering value.

2. Excellent dimensional accuracy and consistency

Through precise molds and highly controllable processes, die-castings possess excellent dimensional stability and interchangeability, providing a reliable guarantee for modern assembly lines and serving as the foundation for high-quality large-scale manufacturing.

3. Superior mechanical properties and surface quality

Solidification under high pressure makes the casting structure dense, with high strength and hardness.

The surface of the casting is smooth and can be directly subjected to various aesthetic surface treatments (such as spraying, electroplating, anodizing, etc.), meeting the appearance requirements of consumer electronic products.

4. Promote lightweighting and sustainable development

It mainly uses lightweight materials such as aluminum alloy and magnesium alloy, and is a key technology for achieving weight reduction and energy conservation in transportation vehicles, especially electric vehicles.The materials are recyclable and in line with the concept of green manufacturing.

The Basic Process Flow of Die Casting

1. Mold closing: After cleaning the mold and spraying the mold release agent, lock the two parts of the mold under high pressure to form a sealed cavity.

2. Injection: Molten metal is filled into the mold cavity at an extremely fast speed and high pressure through an injection system.

3. Pressure holding and cooling: After injection, maintain the pressure to compensate for the shrinkage of the metal during solidification, while the mold cools to solidify the casting.

4. Mold opening: After the casting has initially cooled and solidified, separate the two parts of the mold.

5. Ejection: The ejector pin mechanism inside the mold operates to automatically push the formed casting out of the mold.

6. Post-treatment: Remove excess materials such as gates and flash, and carry out grinding, shot blasting, machining and other treatments to obtain the finished product.

2. The Main advantages and disadvantages of Die Casting

· Advantages:

· High efficiency: Fast production rhythm and high degree of automation.

· High precision and complexity: Capable of manufacturing parts with threads, inserts, and complex internal structures.

· Excellent surface quality: The surface of the casting is smooth and can usually be used directly or only requires a small amount of processing.

· High material utilization rate: The gate and waste can be remelted and reused.

· High strength: Solidifies under pressure, with a dense structure and excellent mechanical properties.

· Disadvantages:

· Huge initial investment: The cost of molds is extremely high.

· Only suitable for large-scale production: to spread out the high mold costs.

· Material limitations: Limited to specific non-ferrous metal alloys, not suitable for high-melting-point metals such as iron and steel.

· Possible porosity: High-speed filling may entrap air, affecting the compactness and heat treatability of the parts (but this can be improved through techniques such as vacuum die-casting).

Anxin’s Ability in Die Casting

1. Full-process solution, focusing on the core

One-stop service: We offer a complete vertically integrated supply chain, covering mold design and manufacturing, precision die-casting, CNC finishing, surface treatment (such as spraying and anodizing), and final assembly. You don’t need to manage multiple suppliers, making communication more efficient, responsibilities more unified, and delivery dates more guaranteed.

2. Technical strength and R&D support

· Advanced technological capabilities: We employ real-time controlled die-casting machines, equipped with advanced processes such as vacuum die-casting and local extrusion, which can effectively reduce porosity, enhance the density and mechanical properties of castings, and meet the demands of high-demand structural components.

.Molds are our core competitiveness: we have a senior mold design team and high-precision mold processing centers. We not only manufacture molds, but also focus on optimizing the pouring and discharging system to ensure product quality from the source, improve yield and extend the service life of molds.

· Materials Science Support: Proficient in the properties of various materials such as aluminum alloys, zinc alloys, and magnesium alloys, we can provide professional material selection and optimization suggestions based on your product performance (such as strength, thermal conductivity, corrosion resistance), cost, and process requirements.

3. Large-scale and flexible production capacity

· Scale and Efficiency: With a cluster of die-casting islands ranging from medium and small tonnage to large tonnage, we can not only handle large orders but also reduce costs and ensure stable supply through large-scale production.

· Flexible response: Meanwhile, we possess rapid mold change (SMED) capabilities and flexible production lines, which can efficiently handle the trial production and order demands of small and medium-sized batches and multiple varieties, facilitating the rapid iteration and market launch of your new products.

4. Cost optimization and value co-creation

· Comprehensive cost advantage: With process optimization, high yield rate and full-process independent production, we can provide you with a competitive overall cost while ensuring quality.

· Value Engineering Services: We are not only manufacturers but also partners. Our engineering team is willing to get involved early (ESI), providing manufacturability analysis (DFM) from the product design stage to help optimize the structure, reduce material usage, simplify the process, and help you reduce costs and increase efficiency.

A Panoramic View of Die-Casting Processes

Selection logic

· Seeking speed and complexity → High-pressure die-casting

· Seek strength and density → Low-pressure/vacuum die casting

· Seeking ultimate performance → Semi-solid/extrusion die casting

· Seeking disruptive design → Integrated die-casting

Die Casting Frequently Asked Questions (FAQs)