Mold Manufacturing

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What is die casting mold manufacturing?

Die-casting materials, die-casting machines, and molds are the three essential elements in die-casting production, and none of them can be omitted. The so-called die-casting process refers to the organic and comprehensive application of these three elements to stably, rhythmically, and efficiently produce qualified castings—even high-quality ones—that meet the requirements of drawings or agreements in terms of appearance, internal quality, and dimensions.

A die-casting mold is a tool for casting metal parts, and it is a tool used to complete the die-casting process on a special die-casting and forging machine. The basic die-casting process is as follows: first, molten metal is poured into the mold cavity at a low or high speed. The mold has a movable cavity surface, and pressure forging is performed during the cooling process of the molten metal. This not only eliminates the shrinkage and looseness defects of the blank but also makes the internal structure of the blank achieve broken grains in a forged state, thereby significantly improving the comprehensive mechanical properties of the blank.

Components of Die-Casting Molds

Molding parts (movable and fixed mold cores, molding inserts, core-pulling cores, etc.)
Mold base parts (movable and fixed mold clamping plates, A/B plates, pallets, mold feet)
Bypass system (sprue bushings, spreaders, cross runners, inlets and outlets)
Overflow system (overflow grooves, exhaust grooves)
Ejection mechanism (ejector pins, ejector pin fixing plates, ejection plates, return pins)
Guide parts (guide pillars, guide sleeves, middle guide pillars, middle guide sleeves)
Core-pulling mechanism (core-pulling slides, angle pins, clamping blocks, springs, etc.)
Others (cooling systems, heating systems, reinforcing pillars, etc.)

Die Casting Mold Design Process

Process Analysis and Planning:
- Conduct a process analysis based on indicators such as the material used for the product, product shape, and precision requirements to determine the die casting process.
Cavity Layout and Parting Surface Design:
- Determine the positioning of the product within the mold cavity.
- Design the parting surface, overflow system, and gating system.
Core Assembly and Fixing Method Design:
- Plan the assembly and fixing methods for each movable core.
Core Pulling System Design:
- Calculate the core pulling distance and required force.
Ejection Mechanism Design:
- Design the ejection system for part removal.
Die Casting Machine Selection and Mold Base Design:
- Select an appropriate die casting machine.
- Design the mold base and cooling system.
Dimension Verification and Technical Drawing:
- Verify the relative dimensions between the mold and die casting machine.
- Create technical drawings for the mold and all components.
Design Finalization:
- Complete the design documentation.

Advantages of Die Casting Mold Manufacturing and Molding Services

High Dimensional Accuracy: Achieves precise tolerances.
High Productivity: Enables rapid production with automation capabilities.
Excellent Surface Finish: Reduces the need for post-processing.
Suitability for Mass Production: Efficient for large volume manufacturing.
Minimal Post-Machining: Parts require little finishing after molding.
Cost-Effective Automation: Reduces labor costs through automation.
Superior Repeatability: Ensures consistency across production runs.
Lower Waste: Generates less scrap compared to traditional processes like CNC machining.
Material Efficiency: Minimizes material waste.

Applications

Parts manufactured using our mold-making services are used in industries including construction, food and beverage, doors and windows, automotive, household appliances, electronics, telecommunications, etc. Key components include automotive molds, cookware parts, and LED lighting components.

Online Mold Manufacturing Services

We provide mold manufacturing solutions for various industries, including LED lighting, cookware, automotive die-casting, etc. Our main services cover thin-wall or other die-casting mold manufacturing, die-casting, investment casting, sand casting, and CNC machining. With years of experience, we are capable of producing customized, cost-effective aluminum die-castings, zinc die-castings, and magnesium parts according to customers' specifications, drawings, or samples. Equipped with advanced technology, highly skilled employees, and using high-quality molds and high-pressure die-casting processes, we ensure that the mold parts are offered at the most competitive prices with the highest quality. Whether you need rapid mold manufacturing or mass production mold manufacturing with strict tolerances, our team of experienced experts can provide cost-effective solutions at every stage. Contact our expert team to get the price for your mold/mold manufacturing services, and we will offer you a quotation for die-casting and mold manufacturing within 24 hours!

Die Casting Mold Design and Manufacturing: How to Make Die Casting Molds

Die casting involves numerous considerations, but the design of die casting mold components is of utmost importance. Proper design can result in lower initial costs, higher production quality, shorter cycle times, and rapid assembly. As a resource for experienced engineers and product designers, we have individual experts or professional teams who can assist you in developing die-cast parts from scratch. Our team of die casting mold design engineers specializes in using CAD, CAE, and CAM for drafting, typically employing software such as SOLIDWORKS, PRO ENGINEER, UNIGRAPHICS, and MOLD FLOW analysis tools.

Global Die-Casting Mold Manufacturing Services

XS is a global manufacturer of precision components for traditional and multi-slide die casting. Our engineers provide design solutions for various industries, including consumer electronics, automotive, healthcare, and more. When our engineers are involved in projects at an early stage, they can assist in designing tools and parts specifically tailored for mass production. All our clients receive insights and expertise throughout all stages of the project. Contact our engineering team today to request a quote.

Seven Typical Processes of Die-Casting Manufacturing:

Step 1: Product DFM (Design for Manufacturability) and Mold Design
Step 2: Procurement of Mold Steel and Other Accessories
Step 3: CNC Machining
Step 4: Heat Treatment
Step 5: Wire Cutting / EDM (Electrical Discharge Machining) / Milling / Drilling
Step 6: Mold Fitting, Assembly, and Trial Run
Step 7: Refinement, Polishing, and Texturing

If the final cast product meets our specifications, it is time to polish and texture the mold. Then the entire process is completed.

Design for Manufacturability Content

Multi-slide and conventional die casting: We offer two different types of molds: multi-slide and conventional. Each has its own unique advantages, and our skilled engineers can help determine the most suitable tooling for each project.

Whether the product structure has difficulties and needs modification or simplification; whether undercut positions can be eliminated.
Consider form and position tolerances as well as mold design. If there are geometric tolerances, try to keep them on the same side of the mold, such as the front mold, rear mold, or tail row.
Confirmation of the product’s draft angles and R angles.
Regardless of whether there are thin-walled or hard-to-form areas on the product, the product design needs to be optimized.
Whether the thin structure at the hole position has a risk of breaking and needs reinforcement.
Whether the product is prone to corrosion, and whether cooling or product structure optimization is required.
Whether the product can be designed with reduced material to lower production costs.
Does the product tolerance require post-processing? Are machining allowances and machining positioning devices added at the machining positions?
Whether the product needs to add process points for surface treatment.
If stamping is required for post-processing, are there stamping mold positioning points?
Whether the processing area of the product can be simplified and directly produced by the mold, such as corner-avoiding grooves (corners that cannot be cleaned by large milling cutters).
Whether the product’s gating position and nozzle removal method are reasonable, whether there is a risk of edge chipping, and whether they are easy to remove.
Whether the design of the slag pocket position is reasonable and convenient for grinding and polishing.
The mold number of the product, the arrangement method of the product, and the selection of die casting machine tonnage.
Whether the product has a date code and cavity number.
Whether the product’s ejector pin position is reasonable and will affect the product’s appearance, such as ejector pin marks, ejection bulges, etc.
Whether the design of the parting line position is reasonable and convenient for processing and removal.
Whether the weak parts of the product need to be strengthened, such as adding bridges (to be removed after processing).
If the tolerance requirements are too high, a tolerance review is required to strive for the customer to relax their tolerance requirements.

Whether you only need product design drawings, mold manufacturing, or precise specifications for the final die castings, XS can meet your needs with competitive prices, excellent efficiency, and top-tier customer service.