Capabilities
Die Casting Services
The Premier Original – source Factory of Precision Die Casting in China. Manufacture precise, complex, high – quality and tough metal parts at low cost.
WHY CHOOSE CASTMOLD?
CASTMOLD, a China-based aluminum die casting manufacturer, proudly offers high-quality products in die casting manufacturing industry. From tooling design to casting parts manufacturing, finishing, and packaging, we provide comprehensive and cost-effective solutions for all your aluminum die casting needs.
ISO 9001:2015 quality certification
Material Certification, Certificate of Compliance, Advanced Inspection
Hardware Installation, Mechanical Assembly
1-Stop precision aluminum die casting solution provider
ONE STOP DIE CASTING SERVICE
We offer a wide range of services other than just die casting. Our one-stop service Starts from rapid prototyping to high quality surface finishing. We help you get the final product with ease and here in one place.
Die Cast Surface Finishing
Matte Finish In-House: Get a consistent matte finish for your die-casting and machined parts with our cleaning and shot blasting services.
Protective and Decorative Finishes: Choose from outsourced anodizing (for corrosion resistance), powder coating & liquid painting (for durability and color), and silk screening, pad screening, & laser carving (for branding and identification).
Convenience: Streamline your process by leveraging our complete range of finishing solutions.
Die Casting Tooling
Seamless Control for Faster Results: Our in-house tooling capabilities streamline the entire die casting production. We handle design, fabrication, and maintenance under one roof, eliminating delays and miscommunications common with outsourced tooling.
Proactive Problem-Solving: Our expert mold engineers go beyond just reviewing your drawings. Cutting-edge mold flow analysis proactively identifies potential issues, saving you time and money during production.
Aluminum Die Casting
Your Partner in Precision: At Sunrise Metal, we understand that precision aluminum die casting is critical to your product’s success. Our 23+ years of experience ensure meticulous attention to detail and tolerances your project demands.
Problem-Solvers, Not Just Manufacturers: Tap into our seasoned engineering team for support throughout your project. We offer design collaboration, proactive solutions, and a commitment to finding the optimal path forward.
Secondary CNC Machining
Expand Capabilities: We offer more than just die casting. Tap into our comprehensive service, including precision CNC machining for intricate designs and demanding tolerances.
Accuracy: Our high-tech equipment and expertise ensure exceptional precision, achieving tolerances down to ±0.0015mm (JIS B6336).
Complex Projects: We excel in high-mix, low to medium-volume projects where flexibility and customization are critical.
Die Cast Surface Finishing
Matte Finish In-House: Get a consistent matte finish for your die-casting and machined parts with our cleaning and shot blasting services.
Protective and Decorative Finishes: Choose from outsourced anodizing (for corrosion resistance), powder coating & liquid painting (for durability and color), and silk screening, pad screening, & laser carving (for branding and identification).
Convenience: Streamline your process by leveraging our complete range of finishing solutions.
Die Casting Materials
- A380 Aluminum
- ADC12 Aluminum
- A383 Aluminum
- ADC10 Aluminum
- A390 Aluminum
- Zamak 5 Zinc Alloy
- A356 Aluminum
- Zamak 3 Zinc Alloy
DIE CAST PARTS ENGINEERING SUPPORT
Our dedicated and experienced engineering team will help your business throughout the whole project from early concept to full production.
CastMold’s engineers use computer-aided engineering (CAE) and with their rich technical experience, they can optimize the design for rapid prototypes, die-casting tooling, and casting parts. Moreover, our engineers are professional in the application of CAE including:
- Pro/Engineer and Pro/Manufacture to ensure feasibility for your products’ design, tool design, and production.
- Proficient at working with CAD/CAM files from the virtual system
- Simulation flow analysis to predict how the mold will fill, solidify, and cool-reducing the risk of defective die-casting parts.
- Valued engineering solutions to help reduce costs throughout the manufacturing process
PROCESS CONTROL FOR DIE CAST COMPONENTS
Our quality team rigorously monitor the entire manufacturing process of die-cast components, from raw materials to finished product delivery, ensuring customer needs and satisfactions.
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DIE CASTING PRODUCTS GALLEY
Whether you need small precision die castings or large complex parts, we have the expertise and capability to produce high quality products for different applications.
Hear How We Solve Our Customers’ Toughest Challenges
We prioritize listening to our clients, valuing their insights, and leveraging their feedback to continually enhance our products and services.
CastMold FAQ GUIDE
Looking for the ideal solution for high or low to medium volume production of your products? Look no further than an Aluminum Die Casting Supplier. With over a decade of experience, CastMold in China excels in aluminum die casting, offering fast and reliable solutions for your project needs.
Can you design my parts and execute mold flow analysis for aluminum die casting production?
Yes, we have experienced designers and the necessary hardware required to design parts for you. Additionally, we can conduct effective simulations for mold flow analysis in advance. Our talented engineers can design your parts with a high degree of accuracy and optimize them for easier production, cutting down on costs.
Can you provide PPAP support?
Absolutely. The Production Part Approval Process (PPAP) is an essential part of various industries, and we’ll guide you through the entire approval process, ensuring you don’t have to worry about it.
How does CastMold control the quality of the production process?
CastMold, as professional aluminum die casting factory, we maintain a superior quality management system certified by ISO 9001 standards. We uphold optimum quality control in all stages of production, ensuring maximum quality for the parts we produce.
How do you ensure part traceability?
Every production batch is assigned a Batch Control Card, meticulously recording essential details. Additionally, each part receives a unique identification through labeling, printing, or laser etching, ensuring comprehensive traceability throughout the production process.
What are vibrations of die casting?
In the realm of die casting, vibrations are defined as mechanical oscillations that take place within die casting machines and their corresponding molds.
Vacuum Pressure Casting: In this particular casting process, a vacuum is generated within the mold cavity with the aim of reducing air entrapment and porosity to the greatest extent possible. However, vibrations occurring in such a setting have the potential to disrupt the established vacuum, thereby giving rise to various defects in the final manufactured product.
Low Pressure Casting: In this method, the metal is introduced into the mold under relatively low pressure. This process is vulnerable to the influence of vibrations, as they can interfere with the steady flow of the molten metal. Consequently, this impact on the flow can have an adverse effect on the consistency and overall integrity of the resulting cast.
Semi-Solid Die Casting: This process entails injecting semi-solid metal into the mold. Vibrations in this context can exert an influence on the thixotropic characteristics of the metal. As a result, they can affect the pattern in which the mold is filled and ultimately impact the properties of the final part that is produced.
Squeeze Die Casting: During this casting process, additional pressure is applied following the initial filling stage. The purpose of this additional pressure is to enhance the density and mechanical properties of the cast. However, if vibrations occur during this specific phase, they can lead to an uneven application of pressure, which in turn can cause inconsistencies in the final outcome.
Die casting design considerations?
When it comes to designing parts for die casting, there are several crucial factors that need to be taken into account to guarantee both excellent performance and ease of manufacturability.
Wall Thickness: It is essential to maintain a uniform wall thickness throughout the part. This enables even cooling and solidification, thereby minimizing the chances of defects such as warping or the development of internal stresses. While thinner walls are favored as they lead to faster cooling and save on material, their practicality hinges on the specific metal being used as well as the complexity of the part.
Draft Angles: Draft angles should be incorporated into the design. These angles facilitate the effortless removal of the casting from the die. Generally speaking, a minimum draft angle ranging from 1 to 2 degrees is required, with the exact angle depending on the depth of the part.
Fillet and Radii: Fillets and radii need to be included in the design to get rid of sharp corners and edges. Sharp corners can act as stress concentration points and the origin of cracks. Moreover, this modification also improves the flow of the molten metal within the die.
Gating System: An efficient gating system must be designed to ensure the proper flow of the molten metal into the die. This helps in minimizing turbulence and preventing air from getting trapped. The placement of the gates has a significant impact on the distribution of the material and the overall quality of the part.
Venting: Adequate venting arrangements must be made to allow air and gases to escape from the mold cavity during the metal injection process. This is crucial in preventing porosity and ensuring complete filling of the mold.
Simplifying Geometry: The geometry of the part should be simplified as much as possible. This is to avoid undercuts and complex features that would necessitate intricate die mechanisms. Such complex features can escalate tooling costs and make the casting process more complicated.
Is it feasible to carry out post-machining on die cast parts?
Indeed, post-machining of die cast parts is not only a viable option but is frequently indispensable in order to attain the requisite precision and surface finishes that die casting by itself may fall short of providing. Through post-machining, it becomes possible to achieve more stringent tolerances and surfaces with a higher degree of smoothness, both of which are of vital importance when it comes to meeting high-performance and aesthetic demands.
Typical post-machining procedures encompass drilling, milling, and CNC machining. These processes are employed to refine the characteristics of the die cast part to precisely meet the specified requirements.
Moreover, post-machining has the ability to rectify any minor flaws that might emerge during the casting process, such as porosity or surface blemishes. It also makes it feasible to incorporate complex features and intricate details that cannot be accomplished solely through the casting process.
By combining die casting with post-machining, manufacturers can take full advantage of the speed and cost-effectiveness of die casting for producing the rough shape, while simultaneously attaining the precision associated with CNC machining for crucial dimensions and surface finishes.
