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

A die casting factory is a specialized manufacturing hub that transforms molten metals into high-precision, complex parts using high-pressure molding technology. Unlike general machining shops, it focuses exclusively on the pressure casting process—turning liquid aluminum, zinco, or magnesium alloys into components that power industries from automotive to medical devices. But what exactly happens inside a die casting factory? Quali funzionalità principali lo distinguono dagli altri produttori? E come garantisce una qualità costante per le parti prodotte in serie?? Questo articolo risponde a queste domande con approfondimenti dettagliati sui flussi di lavoro, tecnologie, e applicazioni industriali.

1. Attività principale: Il flusso di lavoro end-to-end della pressofusione

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:

UN. Fare un passo 1: Preparazione del materiale & Raffinazione

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

• Gestione delle materie prime: Receive metal ingots (PER ESEMPIO., ADC12 alluminio, Carichi 5 zinco) and sort them by alloy grade to avoid cross-contamination.
• Fusione & Controllo della temperatura: 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.
• Raffinazione & Degassante: Remove impurities (oxide slag, foreign particles) via ceramic foam filters (20–30 PPI). Per leghe di alluminio, use rotary degassing rods (400–600 rpm) ridurre il contenuto di idrogeno a <0.2cc/100g—prevents porosity in finished parts.

B. Fare un passo 2: Gestione degli stampi & Preparazione

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

• Design dello stampo & Produzione: In-house mold workshops use CNC machining centers (precisione ±0,005 mm) ed EDM (Lavorazione a scarica elettrica) to create molds from high-strength tool steel (PER ESEMPIO., Acciaio H13). Molds include cooling water channels (spaced 15–20mm apart) to speed up solidification.
• Preriscaldare & Lubrificazione: 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.
• Manutenzione della muffa: 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. Fare un passo 3: Stampaggio pressofusione

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

• Machine Selection: Utilizzo hot chamber machines (50–200 tons) for zinc alloys (fast cycle time: 15–30 seconds/part) E macchine da camera fredda (200–1,200 tons) for aluminum/magnesium alloys (handles high melting points).
• Iniezione & Solidificazione: Inject molten metal into mold cavities at 5–150MPa pressure and 2–5m/s speed. Maintain pressure during solidification (tempo di trattenimento: 10–20 secondi) to compensate for shrinkage—ensures part density ≥99.5%.
• Automated Demolding: Use robotic arms (Tempo del ciclo <5 Secondi) to remove parts from molds. This reduces human error and prevents damage to delicate components (PER ESEMPIO., thin-walled electronic housings).

D. Fare un passo 4: Post-elaborazione & Ispezione di qualità

Finishing steps ensure parts meet customer specifications:

• Taglio & Sfacciato: Cut off gate residues and runner systems with hydraulic trimmers (per parti di alluminio) or laser cutters (for precision zinc parts). Remove burrs with ultrasonic cleaning (Ra <1.6μm surface roughness).
• Trattamento superficiale: Offer options like anodizing (per resistenza alla corrosione), rivestimento in polvere (per l'estetica), o placcatura (per resistenza all'usura). Per parti mediche, use passivation to meet biocompatibility standards (Iso 10993).
• Quality Testing: Conduct 3 levels of inspection:

1. Ispezione visiva: Verificare la presenza di difetti di superficie (graffi, pores) with 10× magnifying glasses.
2. Dimensional Testing: Usa CMM (Coordinare la macchina di misurazione) per verificare le tolleranze (±0.1mm for standard parts).
3. Internal Testing: Use X-ray flaw detection to check for hidden porosity (acceptance standard: ≤2% pore volume).

2. Capacità fondamentali: Cosa rende unica una fabbrica di pressofusione?

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

3. Industrie chiave dei servizi: Dove vengono utilizzate le parti pressofuse

Die casting factories supply critical components to 5 importanti industrie, Ognuno con requisiti unici:

UN. Industria automobilistica (40–50% dei ricavi)

• Prodotti: Supporti del motore, Cali di trasmissione, EV battery pack frames, steering gear casings.
• Requisiti: Leggero (aluminum parts reduce vehicle weight by 10–15%), alta resistenza (tensile strength ≥280MPa), e resistenza alla corrosione.
• Esempio: A factory might produce 1 million aluminum battery frames annually for a major EV manufacturer, meeting IP68 waterproof standards.

B. Elettronica di consumo (20–25% dei ricavi)

• Prodotti: Mobile phone middle frames, cerniere per laptop, wireless headphone charging compartments, Dissipatori di calore a LED.
• Requisiti: Precisione (tolleranza ± 0,05 mm), dimensioni ridotte (10–500g), and good surface finish (anodized or plated).
• Esempio: Supplies zinc alloy charging port housings to a smartphone brand—100,000 units/week with zero surface defects.

C. Elettrodomestici (10–15% dei ricavi)

• Prodotti: Air conditioning compressor housings, washing machine drum bearing seats, cerniere per porte del frigorifero.
• Requisiti: Tightness (no water leakage), Resistenza all'ambiente, e basso costo.
• Esempio: Produces aluminum compressor housings for a home appliance company—parts pass 10,000-cycle vibration tests.

D. Apparecchiature di comunicazione (5–10% delle entrate)

• Prodotti: 5G base station cooling modules, conchiglie del router, fiber optic connector housings.
• Requisiti: Heat dissipation (alta conduttività termica), electromagnetic shielding, and weather resistance.
• Esempio: Manufactures magnesium alloy cooling modules for 5G towers—parts withstand -40°C to +85°C temperature ranges.

E. Dispositivi medici (3–5% of Revenue)

• Prodotti: CT machine rotating frames, maniglie degli strumenti chirurgici, insulin pump casings.
• Requisiti: Biocompatibilità (Iso 10993), alta precisione (± 0,03 mm), and easy sterilization.
• Esempio: Supplies titanium-aluminum alloy surgical tool handles to a medical device firm—parts pass autoclave sterilization (134° C., 20 minuti) 1,000+ volte.

4. How Die Casting Factories Compare to Other Manufacturing Processes

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

5. Yigu Technology’s Perspective on Die Casting Factories

Alla tecnologia Yigu, 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) Controllo del processo guidato dall'IA (real-time adjustment of injection speed/pressure reduces defect rates to <1.5%); 2) Green manufacturing (vacuum die casting cuts energy use by 20%, E 95% of scrap is recycled); 3) Cross-process integration (morire casting + MACCHING CNC + surface treatment on one line shortens lead time by 40%).

Per client automobilistici, produciamo 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 settimane. Our goal is to be more than a supplier—we’re a partner that helps clients optimize designs for cost, qualità, e sostenibilità.

Domande frequenti

1. Qual è la quantità minima dell'ordine (Moq) for a die casting factory?

MOQ depends on mold costs: Per parti standard (PER ESEMPIO., generic brackets), MOQ is 10,000–50,000 units to offset mold expenses. Per parti personalizzate, we offer flexible MOQ (1,000–5.000 unità) 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 settimane (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 settimane (no mold lead time).

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

Yes—most die casting factories (compresa la tecnologia Yigu) integrate CNC machining into their workflow. This is critical for parts that need ultra-precise features (PER ESEMPIO., 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.