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? 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, tecnologias, 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:

UM. Etapa 1: Preparação do material & Refino

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

• Manuseio de matéria -prima: Receive metal ingots (Por exemplo, ADC12 aluminum, Cargas 5 zinco) and sort them by alloy grade to avoid cross-contamination.
• Fusão & Controle de temperatura: Aqueça lingotes em fornos a gás ou elétricos a temperaturas precisas (680–720°C para alumínio, 380–420°C para zinco). Use termopares digitais para manter a tolerância de ±5°C – fundamental para um fluxo consistente.
• Refino & Desgaseificação: Remover impurezas (escória de óxido, partículas estranhas) através de filtros de espuma cerâmica (20–30 PPI). Para ligas de alumínio, use hastes rotativas de desgaseificação (400–600 rpm) reduzir o teor de hidrogénio para <0.2cc/100g — evita a porosidade nas peças acabadas.

B. Etapa 2: Mold Management & Preparação

Os moldes são o “coração” da fundição sob pressão – as fábricas investem pesadamente em seu design, manutenção, e otimização:

• Design de molde & Fabricação: Oficinas internas de moldes usam centros de usinagem CNC (accuracy ±0.005mm) e EDM (Usinagem de descarga elétrica) to create molds from high-strength tool steel (Por exemplo, Aço H13). Molds include cooling water channels (spaced 15–20mm apart) to speed up solidification.
• Pré -aquecimento & Lubrificação: 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.
• Manutenção do molde: 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. Etapa 3: Die Casting Molding

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

• Seleção de Máquina: Usar máquinas de câmara quente (50–200 tons) for zinc alloys (fast cycle time: 15–30 seconds/part) e máquinas de câmara fria (200–1,200 tons) for aluminum/magnesium alloys (handles high melting points).
• Injeção & Solidificação: Inject molten metal into mold cavities at 5–150MPa pressure and 2–5m/s speed. Maintain pressure during solidification (tempo de espera: 10–20 segundos) to compensate for shrinkage—ensures part density ≥99.5%.
• Automated Demolding: Use robotic arms (tempo de ciclo <5 segundos) to remove parts from molds. This reduces human error and prevents damage to delicate components (Por exemplo, thin-walled electronic housings).

D. Etapa 4: Pós-processamento & Inspeção de qualidade

Finishing steps ensure parts meet customer specifications:

• Aparar & Deburrendo: Cut off gate residues and runner systems with hydraulic trimmers (Para peças de alumínio) or laser cutters (for precision zinc parts). Remove burrs with ultrasonic cleaning (Rá <1.6μm surface roughness).
• Tratamento de superfície: Offer options like anodizing (para resistência à corrosão), revestimento em pó (para estética), ou revestimento (para resistência ao desgaste). Para peças médicas, use passivation to meet biocompatibility standards (ISO 10993).
• Quality Testing: Conduct 3 levels of inspection:

1. Inspeção visual: Check for surface defects (arranhões, pores) with 10× magnifying glasses.
2. Dimensional Testing: Use CMM (Máquina de medição de coordenadas) Para verificar as tolerâncias (±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 Principais indústrias, cada um com requisitos únicos:

UM. Indústria automotiva (40–50% of Revenue)

• Products: Montagens do motor, Capas de transmissão, EV battery pack frames, steering gear casings.
• Requisitos: Leve (aluminum parts reduce vehicle weight by 10–15%), alta resistência (tensile strength ≥280MPa), e resistência à corrosão.
• Exemplo: A factory might produce 1 million aluminum battery frames annually for a major EV manufacturer, meeting IP68 waterproof standards.

B. Eletrônica de consumo (20–25% of Revenue)

• Products: Quadros intermediários de celular, Laptop depende, wireless headphone charging compartments, Afotos de calor de LED.
• Requisitos: Precisão (tolerância ± 0,05 mm), tamanho pequeno (10–500g), and good surface finish (anodized or plated).
• Exemplo: Supplies zinc alloy charging port housings to a smartphone brand—100,000 units/week with zero surface defects.

C. Aparelhos domésticos (10–15% of Revenue)

• Products: Air conditioning compressor housings, washing machine drum bearing seats, dobradiças da porta da geladeira.
• Requisitos: Tightness (no water leakage), Resistência ao impacto, e baixo custo.
• Exemplo: Produces aluminum compressor housings for a home appliance company—parts pass 10,000-cycle vibration tests.

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

• Products: 5G base station cooling modules, Cascas de roteador, fiber optic connector housings.
• Requisitos: Heat dissipation (alta condutividade térmica), electromagnetic shielding, and weather resistance.
• Exemplo: Manufactures magnesium alloy cooling modules for 5G towers—parts withstand -40°C to +85°C temperature ranges.

E. Dispositivos médicos (3–5% of Revenue)

• Products: CT machine rotating frames, alças de instrumentos cirúrgicos, insulin pump casings.
• Requisitos: Biocompatibilidade (ISO 10993), alta precisão (± 0,03 mm), and easy sterilization.
• Exemplo: Supplies titanium-aluminum alloy surgical tool handles to a medical device firm—parts pass autoclave sterilization (134° c, 20 minutos) 1,000+ vezes.

4. How Die Casting Factories Compare to Other Manufacturing Processes

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

5. Yigu Technology’s Perspective on Die Casting Factories

Na 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) Controle de processo orientado a 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 (morrer de elenco + Usinagem CNC + surface treatment on one line shortens lead time by 40%).

Para clientes automotivos, nós produzimos 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 semanas. Our goal is to be more than a supplier—we’re a partner that helps clients optimize designs for cost, qualidade, e sustentabilidade.

Perguntas frequentes

1. Qual é a quantidade mínima de pedido (MOQ) for a die casting factory?

MOQ depends on mold costs: Para peças padrão (Por exemplo, generic brackets), MOQ is 10,000–50,000 units to offset mold expenses. Para peças personalizadas, we offer flexible MOQ (1,000–5.000 unidades) 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 semanas (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 semanas (no mold lead time).

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

Yes—most die casting factories (incluindo a tecnologia YIGU) integrate CNC machining into their workflow. This is critical for parts that need ultra-precise features (Por exemplo, 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.