Die Casting Service China | Urethane Casting

Position：

CAST PROTOTYPES

AND PRODUCTION

PARTS ARE USED FOR

The prototype castings and the production parts are the fundamental components in the manufacturing industry, widely used in key links of various industrial fields. From the cast iron cylinder block of automotive engines to the titanium alloy turbine blades in aerospace, from the steel structure nodes in construction engineering to the high-precision aluminum alloy shells of household appliances, casting technology supports the operation of the modern industrial system. In the equipment manufacturing sector, large cast steel pieces form the load-bearing framework of heavy machinery; in the energy industry, high-temperature resistant alloy castings ensure the safe operation of power generation units; and in the daily consumer goods sector, zinc alloy die-cast parts give products exquisite appearance and complex structures. With the development of 3D printing sand mold technology, traditional casting processes are deeply integrating with digital technology, achieving seamless connection from single prototype to batch production, meeting the demand for rapid iteration of complex components in the era of Industry 4.0. Whether it is the rapid verification in the sample development stage or the stable supply in the mass production phase, castings have always been an important link connecting design and manufacturing.

THE CORE PRINCIPLE
OF VACUUM CASTING

Vacuum environment (10-2 to 10-3 Pa)

Avoid the reaction of molten metal with oxygen and nitrogen, and reduce pores and inclusions.

Directional solidification technology

Control the cooling direction to obtain a single crystal/columnar crystal structure (such as aviation turbine blades).

Special mold system

Ceramic shells (alumina, yttrium oxide) or graphite molds, which are heat-resistant and have low reactivity.

KEY
APPLICATION
AREAS

SOME OF OUR
COMMON
CASTING MATERIALS

Die casting technology is widely used in automotive manufacturing (engine blocks, transmission housings), 3C electronics (smartphone frames, heat dissipation components), home appliances (AC compressors, motor housings), and industrial components (hydraulic parts, pump/valve housings). With advantages of high precision, superior strength, and mass production capability, it is particularly suitable for forming complex thin-walled parts. Magnesium/aluminum alloy die-cast components demonstrate outstanding advantages in lightweight applications, with rapidly growing demand for new energy vehicle battery/motor/electronic control housings. Future industry transformation will be driven by semi-solid die casting and mega-sized integrated die casting technologies.

Aerospace

Turbine blades (single crystal nickel-based alloys), spacecraft structural components (titanium alloys).

Medical implant

Artificial joints (CoCrMo alloy), biocompatibility up to ASTM F75 standard.

High-end electronics

Semiconductor copper crucibles (purity 99.9999%), with an 8% increase in wafer yield.

Common casting materials include gray cast iron (HT), ductile iron (QT), cast steel (ZG), cast aluminum alloys (such as ZL101, ZL104), cast copper alloys (such as ZCuSn10Zn2), cast magnesium alloys (such as AZ91D), cast zinc alloys (such as ZA27), as well as gypsum, sand molds, and other non-metallic casting materials. These materials are widely used in the production of castings for automotive components, mechanical equipment, building hardware, daily products, etc. Depending on different usage environments and performance requirements, appropriate casting materials are selected for forming processing in engineering practice.

WHAT IS DIE CASTING?

Die casting is a large-scale manufacturing process that uses high pressure (150-1200 tons) to inject molten metal into steel molds, allowing for rapid cooling and shaping. It is suitable for the production of metal parts with complex structures.

CORE ADVANTAGES

Ultra-high efficiency

The single-piece production cycle can be as short as 30 seconds, suitable for orders of tens of thousands of pieces

Excellent surface quality

Directly reaches a surface finish of Ra1.6μm (can be electroplated/sprayed)

Precise and complex

Tolerance of ±0.1mm, can integrate features such as threads and snap fasteners

Cost advantage

The single-piece cost is only 1/10 of that of CNC processing (for orders over 10,000 pieces)

OUR DIE CASTING PROCESSES SERVICES

Hot chamber die casting

Hot chamber die casting is an efficient metal forming process. The furnace and the injection system are integrated in one design. Zinc, tin and other low-melting-point alloys remain in a molten state in the sealed furnace, and are directly injected into the mold through a swivel pipe. Its working temperature range of 240℃ - 450℃ and the high injection speed of 5 meters per second make it particularly suitable for large-scale production of small precision parts. It is typically applied in fields such as electronic enclosures and hardware accessories, and has the advantages of short cycle time (10 - 30 seconds per mold) and low energy consumption.

Cold chamber die casting

Cold chamber die casting is an efficient metal forming process. Molten metal is kept warm in an independent furnace and is pushed into the mold cavity by a piston. This technology is particularly suitable for the precision casting of high-melting-point alloys such as aluminum, magnesium, and copper. It has the characteristics of fast forming speed (0.1-1 second per piece), high dimensional accuracy (±0.05mm), and excellent surface quality (Ra1.6μm). It is widely used in automotive engine components, 5G communication shells, and other fields that have strict requirements for material performance.

ADVANTAGES AND DRAWBACKS OF DIE CASTING

Advantages

Fast cycle times.

Is suitable for producing complex parts.

Produces parts with high dimensional accuracy.

Produces parts with a smooth surface finish, which lessens the need for post-processing.

Offers repeatable, accurate results with efficient production.

Drawbacks

The cost of equipment and dies can be very expensive.

Is typically unsuitable for ferrous metals or metals with a high melting point.

Designing and tooling new dies is a complex process that can take long before a production run starts.

Up-front costs and lead times may be prohibitively high with small production batches.

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