Cosa fa una fabbrica di pressofusione e quali sono le sue capacità principali?

Una fabbrica di pressofusione è un centro di produzione specializzato che trasforma i metalli fusi in metalli di alta precisione, parti complesse utilizzando la tecnologia di stampaggio ad alta pressione. A differenza delle officine meccaniche generali, it focuses exclusively on the pressure casting process—turning liquid aluminum, zinco, o leghe di magnesio in componenti che alimentano le industrie, dall'automotive ai dispositivi medici. But what exactly happens inside a die casting factory? 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, tecnologie, 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:

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

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

• Raw Material Handling: Receive metal ingots (per esempio., ADC12 aluminum, gli oneri 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.
• Refining & Degasaggio: Remove impurities (oxide slag, foreign particles) via ceramic foam filters (20–30 PPI). For aluminum alloys, use rotary degassing rods (400–600 rpm) to reduce hydrogen content to <0.2cc/100g—prevents porosity in finished parts.

B. Fare un passo 2: Mold Management & Preparazione

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

• Progettazione di stampi & Produzione: In-house mold workshops use CNC machining centers (accuracy ±0.005mm) ed elettroerosione (Lavorazione ad elettroerosione) to create molds from high-strength tool steel (per esempio., Acciaio H13). Molds include cooling water channels (spaced 15–20mm apart) per accelerare la solidificazione.
• Preriscaldamento & Lubrication: 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.
• Mold Maintenance: 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: Die Casting Molding

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 a camera fredda (200–1.200 tonnellate) 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 (holding time: 10–20 secondi) to compensate for shrinkage—ensures part density ≥99.5%.
• Automated Demolding: Use robotic arms (tempo di 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:

• Rifilatura & Sbavatura: Cut off gate residues and runner systems with hydraulic trimmers (per parti in 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 la resistenza alla corrosione), verniciatura a polvere (per l'estetica), o placcatura (per la resistenza all'usura). Per parti mediche, use passivation to meet biocompatibility standards (ISO 10993).
• Quality Testing: Conduct 3 levels of inspection:

1. Ispezione visiva: Check for surface defects (graffi, pores) with 10× magnifying glasses.
2. Dimensional Testing: Use CMM (Macchina di misura a coordinate) 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. 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 principali industrie, ognuno con requisiti unici:

UN. Industria automobilistica (40–50% of Revenue)

• Prodotti: Engine mounts, alloggiamenti di trasmissione, EV battery pack frames, steering gear casings.
• Requirements: 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% of Revenue)

• Prodotti: Mobile phone middle frames, cerniere del computer portatile, wireless headphone charging compartments, Dissipatori di calore per LED.
• Requirements: Precisione (tolleranza ±0,05 mm), piccola dimensione (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% of Revenue)

• Prodotti: Air conditioning compressor housings, washing machine drum bearing seats, refrigerator door hinges.
• Requirements: Tightness (no water leakage), resistenza agli urti, and low cost.
• Esempio: Produces aluminum compressor housings for a home appliance company—parts pass 10,000-cycle vibration tests.

D. Communication Equipment (5–10% of Revenue)

• Prodotti: 5G base station cooling modules, router shells, fiber optic connector housings.
• Requirements: Heat dissipation (elevata 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, manici di strumenti chirurgici, insulin pump casings.
• Requirements: 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+ times.

4. How Die Casting Factories Compare to Other Manufacturing Processes

Die casting factories differ from sand casting, stampaggio, 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 basato sull'intelligenza artificiale (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 (pressofusione + Lavorazione CNC + surface treatment on one line shortens lead time by 40%).

Per i clienti del settore automobilistico, 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 (including Yigu Technology) 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.