What Does a Die Casting Factory Do and What Are Its Core Capabilities?

Eine Druckgussfabrik ist ein spezialisiertes Produktionszentrum, das geschmolzene Metalle in Hochpräzisionsprodukte umwandelt, komplexe Teile mittels Hochdruckformtechnik. Im Gegensatz zu allgemeinen Bearbeitungsbetrieben, Es konzentriert sich ausschließlich auf die Druckgussverfahren– Drehen von flüssigem Aluminium, Zink, oder Magnesiumlegierungen in Komponenten, die Industrien von der Automobilindustrie bis hin zu medizinischen Geräten antreiben. Aber was genau passiert in einer Druckgussfabrik?? What core capabilities set it apart from other manufacturers? And how does it ensure consistent quality for mass-produced parts? This article answers these questions with detailed insights into workflows, Technologien, and industry applications.

1. Core Business: The End-to-End Die Casting Workflow

A die casting factory manages every step from raw material to finished part—no external outsourcing required for key processes. The workflow follows a linear, highly optimized sequence:

A. Schritt 1: Materialvorbereitung & Verfeinerung

This stage ensures molten metal meets strict quality standards for fluidity and purity:

• Rohstoffhandhabung: Receive metal ingots (Z.B., ADC12 aluminum, Lasten 5 Zink) and sort them by alloy grade to avoid cross-contamination.
• Schmelzen & Temperaturregelung: Heat ingots in gas or electric furnaces to precise temperatures (680–720°C for aluminum, 380–420°C for zinc). Use digital thermocouples to maintain ±5°C tolerance—critical for consistent flow.
• Verfeinerung & Degasieren: Verunreinigungen entfernen (oxide slag, foreign particles) via ceramic foam filters (20–30 PPI). Für Aluminiumlegierungen, use rotary degassing rods (400–600 rpm) to reduce hydrogen content to <0.2cc/100g—prevents porosity in finished parts.

B. Schritt 2: Mold Management & Vorbereitung

Molds are the “heart” of die casting—factories invest heavily in their design, Wartung, and optimization:

• Schimmeldesign & Herstellung: In-house mold workshops use CNC machining centers (accuracy ±0.005mm) und EDM (Elektrische Entladungsbearbeitung) to create molds from high-strength tool steel (Z.B., H13 Stahl). Molds include cooling water channels (spaced 15–20mm apart) to speed up solidification.
• Vorheizen & Schmierung: Preheat molds to 180–250°C (depending on alloy) to avoid cold shuts. Spray a thin layer of eco-friendly release agent (5–8μm thick) to ensure easy part removal—prevents surface damage.
• Schimmelbehörde: Inspect molds after every 5,000–10,000 shots for wear. Repair minor scratches with laser cladding; replace worn cores when dimensional deviation exceeds ±0.1mm.

C. Schritt 3: Druckgussformen

The core production stage—high pressure transforms molten metal into finished part shapes:

• Maschinenauswahl: Verwenden Heißkammermaschinen (50–200 Tonnen) for zinc alloys (fast cycle time: 15–30 Sekunden/Teil) Und Kaltkammermaschinen (200–1,200 tons) for aluminum/magnesium alloys (handles high melting points).
• Injektion & Erstarrung: Inject molten metal into mold cavities at 5–150MPa pressure and 2–5m/s speed. Maintain pressure during solidification (Haltezeit: 10–20 Sekunden) to compensate for shrinkage—ensures part density ≥99.5%.
• Automated Demolding: Use robotic arms (Zykluszeit <5 Sekunden) to remove parts from molds. This reduces human error and prevents damage to delicate components (Z.B., thin-walled electronic housings).

D. Schritt 4: Nachbearbeitung & Qualitätsinspektion

Finishing steps ensure parts meet customer specifications:

• Trimmen & Enttäuschung: Cut off gate residues and runner systems with hydraulic trimmers (Für Aluminiumteile) or laser cutters (for precision zinc parts). Remove burrs with ultrasonic cleaning (Ra <1.6μm surface roughness).
• Oberflächenbehandlung: Offer options like anodizing (für Korrosionsbeständigkeit), Pulverbeschichtung (für Ästhetik), oder Plattierung (für Verschleißfestigkeit). Für medizinische Teile, use passivation to meet biocompatibility standards (ISO 10993).
• Qualitätsprüfung: Benehmen 3 levels of inspection:

1. Visuelle Inspektion: Check for surface defects (Kratzer, Poren) with 10× magnifying glasses.
2. Dimensional Testing: Verwenden Sie CMM (Koordinatenmessmaschine) Toleranzen überprüfen (±0.1mm for standard parts).
3. Internal Testing: Use X-ray flaw detection to check for hidden porosity (acceptance standard: ≤2% pore volume).

2. Core Capabilities: What Makes a Die Casting Factory Unique?

Die casting factories stand out from other manufacturers due to 4 key capabilities, tailored to mass production and precision requirements:

3. Key Service Industries: Where Die Casting Parts Are Used

Die casting factories supply critical components to 5 Hauptindustrien, jeweils mit einzigartigen Anforderungen:

A. Automobilindustrie (40–50% of Revenue)

• Produkte: Motorhalterungen, Übertragungsgehäuse, EV battery pack frames, steering gear casings.
• Requirements: Leicht (aluminum parts reduce vehicle weight by 10–15%), hohe Stärke (tensile strength ≥280MPa), und Korrosionsbeständigkeit.
• Beispiel: A factory might produce 1 million aluminum battery frames annually for a major EV manufacturer, meeting IP68 waterproof standards.

B. Unterhaltungselektronik (20–25% of Revenue)

• Produkte: Mittelrahmen für Mobiltelefone, Laptop scharniert sich, wireless headphone charging compartments, LED -Kühlkörper.
• Requirements: Präzision (Toleranz ± 0,05 mm), kleine Größe (10–500g), and good surface finish (anodized or plated).
• Beispiel: Supplies zinc alloy charging port housings to a smartphone brand—100,000 units/week with zero surface defects.

C. Haushaltsgeräte (10–15% of Revenue)

• Produkte: Air conditioning compressor housings, washing machine drum bearing seats, Kühlschrank -Türscharniere.
• Requirements: Tightness (no water leakage), Schlagfestigkeit, und niedrige Kosten.
• Beispiel: Produces aluminum compressor housings for a home appliance company—parts pass 10,000-cycle vibration tests.

D. Kommunikationsausrüstung (5–10% of Revenue)

• Produkte: 5Kühlmodule der G-Basisstation, Router -Muscheln, fiber optic connector housings.
• Requirements: Heat dissipation (hohe thermische Leitfähigkeit), electromagnetic shielding, and weather resistance.
• Beispiel: Manufactures magnesium alloy cooling modules for 5G towers—parts withstand -40°C to +85°C temperature ranges.

E. Medizinprodukte (3–5% of Revenue)

• Produkte: CT machine rotating frames, chirurgische Instrumentengriffe, insulin pump casings.
• Requirements: Biokompatibilität (ISO 10993), hohe Präzision (± 0,03 mm), and easy sterilization.
• Beispiel: Supplies titanium-aluminum alloy surgical tool handles to a medical device firm—parts pass autoclave sterilization (134° C, 20 Minuten) 1,000+ mal.

4. How Die Casting Factories Compare to Other Manufacturing Processes

Die casting factories differ from sand casting, Stempeln, and injection molding facilities in key ways. The table below highlights critical differences:

5. Yigu Technology’s Perspective on Die Casting Factories

Bei Yigu Technology, we believe die casting factories are the backbone of modern manufacturing—bridging raw metal and high-performance end products. Our factory integrates 3 core strengths: 1) AI-gesteuerte Prozesskontrolle (real-time adjustment of injection speed/pressure reduces defect rates to <1.5%); 2) Green manufacturing (vacuum die casting cuts energy use by 20%, Und 95% of scrap is recycled); 3) Cross-process integration (sterben + CNC -Bearbeitung + surface treatment on one line shortens lead time by 40%).

Für Automobilkunden, Wir produzieren 500,000+ aluminum battery frames yearly with IP68 certification. For electronics clients, our zinc alloy parts meet ±0.05mm precision. We’re investing in 3D-printed mold technology to cut NPD time to 3 Wochen. Our goal is to be more than a supplier—we’re a partner that helps clients optimize designs for cost, Qualität, und Nachhaltigkeit.

FAQ

1. Was ist die minimale Bestellmenge (Mindestbestellmenge) for a die casting factory?

MOQ depends on mold costs: Für Standardteile (Z.B., generic brackets), MOQ is 10,000–50,000 units to offset mold expenses. Für benutzerdefinierte Teile, we offer flexible MOQ (1,000–5.000 Einheiten) using shared molds, though per-part costs are slightly higher.

2. How long does it take for a die casting factory to deliver a custom order?

For new custom parts: 4–8 Wochen (includes 3–4 weeks for mold design/manufacturing, 1–2 weeks for sampling, and 1–2 weeks for mass production). For repeat orders: 1–2 Wochen (no mold lead time).

3. Can a die casting factory handle post-processing like CNC machining?

Yes—most die casting factories (einschließlich Yigu -Technologie) integrate CNC machining into their workflow. This is critical for parts that need ultra-precise features (Z.B., threaded holes with ±0.02mm tolerance) that can’t be achieved via die casting alone. We use 5-axis CNC machines to ensure accuracy and efficiency.