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Custom Aluminum Molds Service

Custom Aluminum die cast mold service

3D and 2D product drawings from customers, mold flow simulation steps are necessary. Any potential defects were found during the casting of custom aluminum molds. For example, some parts have A-side and B-side requirements. Particularly for nickel finishing die casting parts. No any air porosity allowances, many of parts will need secondly machining. Have air bulbs occur after machining. Some parts will have very strict tolerances in same axle. This time JSCAST CAE software will offer a great solution. In fact, all aluminum die casting molds manufactory designer need advanced CAE software to help their job, not only the experiences. DFM for customer confirm, the step of raw material quality checking is very important, particularly the mold core material checking. Now material of H13, SKD61, 8407, 1.2344, DH-31 widespread use in Ningbo die casting mold manufactory. We not only checking the chemical composition and mechanical property. The material pure standard is also very important for die casting tooling.

Any impurity contains in the mold core will cause crack problems after thousands of injection times, rough grinding, milling, and rough CNC machining before heat treatment. After heat treatment will take precision grinding and machining. In our pressure die casting mold workshop equipped with a high speeding five-axle machining center. EDM is widespread use in pressure dies casting tools production. This EDM machine's great advantage reduce machining costs and solved the most complicated structure in HPDC dies, the disadvantage will get corrosion problem. So high standard EDM machines choose are critical. Remove oxidation material is a necessary step after EDM machining. Aluminum injection tooling cavity polishing. The roughness of the cavity is also important for pressure die casting tooling injection times. The polishing direction should be the same direction as the mold opening.  

In addition, we can help you solve your questions about custom aluminum molds service.

Some suggestions for Custom Aluminum Molds

1. Perfect mold design is important for mold injection times and superior quality casting components.

2. Prevent molten aluminum alloy directly erosion-corrosion mold cavity. Over 70% of the crack problems caused by part of mold overheating.

3. The injection speed and filling velocity control well when casting gate located in the thick part.

4. For excellent air venting, the parting line better located at the end of the casting system.

5. Let air have time escape from mold cavity before moving die and fixed die closed.

6. Good parting line design should think about how to reduce deburr cost.

7. For strict concentricity casting parts, the products same axle should locate in one cavity whatever female cavity or male cavity. Meet precision requests at the same time highest possible reduce secondly machining cost.

Aluminum Molds

Die casting is a general process for producing engineering metal parts by pressing molten metal into reusable steel molds under high pressure. These dies, called dies, can be designed to produce complex shapes with high precision and repeatability. Parts can be clearly defined, have smooth or textured surfaces, and are suitable for a variety of attractive and available finishes.

Knowledge About Aluminum Die Cast Mold

The basic idea of aluminum die casting is to fill the mold with liquid metal in order to press it into any shape you want to cast. It is the preferred process for most industrial projects that require metal parts. Part of the reason is that although its start-up cost is higher than some other processes, in the long run, aluminum die cast molds can reduce unit costs, especially for mass production. In addition, aluminum die-casting also creates a smooth surface, giving the product a beautiful luster.

One of the most important factors to keep in mind when casting and producing metal products are lowering the temperature. High, uncontrolled temperatures can cause metals to burn and deteriorate, not to mention serious safety issues. Another benefit of aluminum die casting is that it helps alleviate these problems by lubricating the mold during the metal production process, which helps keep it cool and also makes it easier to remove the newly cast metal product after completion.

When the two halves are pressed together, the process is over and the molten metal is pressed into the space created by the two opposite molds. After the casting has solidified, the mold is opened and the part is taken out.

Production Custom Aluminum Molds

Hard tool or aluminum die cast mold is an excellent process to meet higher quantity casting requirements. A larger initial mold investment can significantly reduce recurring casting costs. The production of die castings has highly repeatable characteristics and tolerances.

Everything starts with the casting mold itself. The mold cavity is created by using two machined steel molds. Then, in the casting process, the use of these molds is similar to injection molds.

Manufactured by Aluminum Die Cast Mold With Excellent Repeatability

Die-casting molds use aluminum alloys and zinc alloys to produce castings of the same size that meet your manufacturing needs. Die-casting mold development is a universal process that can produce a large number of small and medium-sized castings.

For more information about die-casting mold manufacturing process, please contact us, we will be happy to provide you with any questions about die-casting molds and many die-casting mold processes.

Aluminum Die Cast Mold Manufacturing Process

Die casting is a manufacturing process that is usually used to produce metal parts with accurate dimensions, well-defined, smooth or textured surfaces. It is achieved by pressing molten metal into reusable metal molds under high pressure. The aluminum die cast molds process follows the follow-up procedures related to die casting mold manufacturing:

1. Create a mold in at least two parts to allow the casting to be removed correctly.

2. These parts are firmly installed in the machine and arranged so that one is fixed and the other is movable.

3. The two are clamped together tightly.

4. Molten metal is injected into the mold cavity, where it solidifies rapidly.

5. The two mold halves are pulled apart and the casting is pushed out.

Compared with sand mold or permanent mold process, HPDC (High Pressure Die Casting) is the fastest method in the industry to produce high-precision non-ferrous metal parts.

High-Pressure Production of Aluminum Die Cast Mold Technical Characteristics

The pressure is concentrated on the high pressure and low pressure molds.

High-pressure casting is a casting aluminum die cast mold method in which alloy liquid is injected into the pressure chamber and the steel mold cavity is filled at high speed to form a hydraulic ejection casting.

Aluminum die cast molds are distinguished from other casting methods by their main characteristics of high pressure and high speed.

1. The molten metal fills the cavity under pressure and opens under upward pressure. The common pressure is 15-100Mpa.

2. The molten metal fills the cavity at high speed, usually 10-50 meters per second, and some exceed 80 meters per second (the linear velocity through the inner gate cavity-the inner gate speed), so the filling time of the molten metal Fill the cavity in a very short time (about 0.01-0.2 seconds).

The Special Features of High Voltage are:

1. Fast filling, high production efficiency.

2. Molded under high pressure, the product has high compactness, high product strength and surface hardness, but the product has a low elongation rate.

3. Good surface finish

4. Production of thin-walled parts, the thinnest die-casting wall thickness can be chrome-plated 0.5mm.

5. The filling is fast, there is a lot of gas involved inside, and the product has poor porosity.

6. Not heat-treatable, the internal gas will expand during heat treatment, causing defects such as bulging or cracking of the product.

7. The processing allowance is small. If the processing volume is too large, the dense layer on the surface will be destroyed, and the internal pores will be exposed, which will reduce the strength of the product.

8. High mold cost and short mold life.

Cold Chamber Die Casting for Robust Parts and Rapid Production

The cold chamber die casting process is the preferred manufacturing method for high melting point metals. Typically, this would include metal alloys of aluminum alloys, zinc alloys, brass and copper. The requirements for cold chamber die casting include an external furnace and a ladle for pouring the molten metal. The cold chamber die casting method is known for its ability to produce denser metal castings.

Die Casting Process

Cold chamber die casting is ideal for high melting point and corrosive metals. In contrast to hot chamber die casting, cold chamber die casting solves corrosion problems by separating the furnace from the injector components. The process begins when molten metal is poured from the furnace into the blast chamber through the pouring hole. Next, the plunger forces the metal through the shot chamber into the mold at a pressure of 2,000 to 20,000 psi. 

For cold chamber die casting, the metal is first heated in a separate furnace to reach a molten state. The molten metal is then transported to a casting machine, which then feeds it into the machine's chambers. The machine uses a pressurized plunger to press the molten metal into the cavity of the mold. This separation process is the direct difference between cold chamber die casting and hot chamber casting.

Advantages of Cold Chamber Casting

Cold chamber die casting is an efficient and cost effective process that can create a wide range of shapes and components compared to other types of manufacturing processes. The cold chamber die casting process can create parts that have a long life and can be designed to complement the visual appeal of surrounding parts. Some of the immediate benefits that the cold chamber die casting process can provide include

Increased strength and weight - Cold chamber die castings are stronger than plastic injection molded parts with the same dimensions. Thin-walled castings are stronger and lighter than other casting methods. In addition, because die castings are not made up of individual parts welded or held together, strength is that of the alloy, not the joining process.

Dimensional accuracy and stability - The process produces durable and dimensionally stable parts, while maintaining tight tolerances and heat resistance.

High speed production - The cold chamber process provides complex shapes within much tighter tolerances than many other mass production processes. Little or no machining is required, and thousands of identical castings can be produced before additional tooling is needed.

Simplifies assembly - Cold chamber die castings provide integral fastening elements such as tabs and studs. Holes can be cored and tapped to drill size, or external threads can be cast.

Multiple finishing techniques - Cold chamber parts can be produced with smooth or textured surface finishes and can be easily plated or finished with minimal surface preparation.

Hot Chamber Die Casting of Low Melting Point Alloys

Hot chamber die casting machines are used primarily for zinc alloys, copper, lead and other low melting point alloys. The injection mechanism of the hot chamber machine is immersed in the molten metal bath of the metal holding furnace. The furnace is connected to the machine by a metal feed system called a gooseneck tube.

As the injection cylinder plunger rises, a port in the injection cylinder opens, allowing the molten metal to fill the cylinder. As the plunger moves down, it seals the port and forces the metal through the gooseneck tube and nozzle to fill the cavity into the mold cavity.

After the metal has solidified in the cavity, the plunger is withdrawn. The mold opens and the casting is ejected.

We can help with low melting point alloys

If you have a project using low melting point alloys, Goal Sure may be able to help. Depending on the needs of your application, Goal Sure can use cold chamber die casting instead of the hot chamber casting process. 

Thin-walled die castings for lightweight, complex aluminum parts

Aluminum thin-wall die casting is a manufacturing process that produces parts with an excellent strength-to-weight ratio compared to parts produced by other manufacturing methods. Aluminum die thin-wall casting is also an efficient and economical process that can create an almost unlimited number of unique product shapes and sizes for industries around the world. Aluminum thin-wall castings are also commonly used to complement the aesthetics of their surrounding parts.

At Goal Sure, we offer industry-leading thin-wall die casting services for your aluminum part needs. For more information on our aluminum thin wall casting service options, please contact us and we will be happy to answer any questions you may have about our thin wall aluminum casting methods.

Thin Wall Die Casting Offers Ideal Strength to Weight Ratio

Thin-wall aluminum die casting produces lighter parts that offer an excellent strength-to-weight ratio. There are many other advantages and disadvantages to the thin-wall aluminum casting method, including

Other thin-wall advantages.

- Net shape part configurations can be achieved.

- High dimensional accuracy can be achieved.

- Rapid production.

- Thinner wall thicknesses can be achieved compared to investment casting.

- Wide range of possible shapes.

- External threads can be cast.

- Holes can be cored to internal tap drill size.

Thin-wall disadvantages.

- Relatively large production volumes are required to make the process cost effective. (However, Goal Sure will work with the customer to mitigate this disadvantage.)

- High initial cost (tooling, setup).

- Minimum wall thickness: 0.040" For small parts.

- Maximum wall thickness: 0.200". In some cases, an acceptable maximum of 0.50".

- Draft radius and fillet required on castings.

- Potential porosity issues.

Aluminum Thin Wall Die Casting Applications

Aluminum-based thin wall castings are used by a wide range of industries around the world to make parts and components with beneficial qualities preferred by customers. Some of the industries that use thin wall casting include

- Automotive


- Engine manufacturing

- Military

- Commercial

In-house die casting mold design and development

Effective die casting can produce thousands of high quality castings in a relatively short period of time while using a single mold. This highly economical and cost effective approach to die casting die design can produce castings of uniform quality and accuracy. Die casting mold development provides high quality, near "net shape" parts at a very cost effective price.

 The process of machining die castings must be fully considered before any die order is issued. Careful evaluation of machining requirements can lead to redesigning net shape die castings or near net shapes, reducing the number of operations.

Contact us for more information on our die casting mold design development options and process.

Die Development Process

Die casting is an automated casting process in which liquid metal is pressed into a mold at high speed under extreme pressure. This casting process is ideal for high volume production of parts and is often used with alloys that have a low melting point. Because permanent metal molds are used in the die casting die process, large, complex parts with low wall thicknesses can be produced.

Die Casting Molds

The die used in the die casting mold design process is made of high quality heat resistant steel. The die is halved to create a cavity into which the liquid metal is pressed during the casting process. Die casting molds are very robust and can typically make over a million parts from a single mold. However, the actual life of the die will depend entirely on the die casting material used.

Advantages of Die Casting Die Development

Die casting utilizes non-ferrous metals such as aluminum alloys or zinc alloys to make parts. The alloy chosen for the application depends on budget, weight and material properties. Other benefits associated with the use of die casting die designs include

High thermal conductivity

High electrical conductivity

Good machinability

Very good EMI/RFI isolation

High corrosion resistance

High strength and hardness

Advantages of Quality Die Casting Tooling Design

When it comes to quality die casting mold development, there are several influencing factors that contribute to the overall success of the process. These factors include

Top-notch engineering, in-house die casting tool design. Management and oversight of all aspects of the tooling by Goal Sure.

Development of injection process parameters: gate size, location, feed rate, fill time, injection pressure, press size.

Parting lines, runners, overflow, venting, cooling.

Minimum and maximum wall thickness.

Selection of mold material and hardness based on mold force calculations.

Premium or high quality H13, Uddeholm Orvar or Dievar.

Flow simulation.

Drafts, radii, fillets.

Create machining inventory.

Other Considerations for Die Casting Mold Design 

Some other factors that should be considered before beginning a die casting mold development project include

Gating calculations, feed rate and fill time.

Press size, clamping force calculations.

Holster selection and calculations.

Venting and overflow.

Establishing casting and technical benchmarks

Creation of machining inventory.

Life of Custom Aluminum Molds

Aluminum die casting molds are currently widely used molds. Due to the long production cycle, large investment, and high manufacturing precision, the cost is relatively high. Therefore, it is hoped that the aluminum die-casting mold has a long service life. However, due to a series of factors such as materials, processing, and use, molds often fail prematurely and are scrapped, resulting in a lot of waste.

The most important factor is the quality of the material, because aluminum alloy die casting molds are more harmful. If the material is not good, the die may be scrapped after 30,000 to 40,000 die castings. From the customer's point of view, the cost of opening an aluminum alloy die-casting mold is very high. If the life is short, the new product may not be profitable; from the perspective of the die casting plant, once it is scrapped, it will inevitably fail to meet the delivery time. There are still many mold problems.

Related reading: 7 Factors That Affect The Life Of Aluminum Die Casting Molds

Cooperate With Trusted Aluminum Die Cast Mold Partners

As mentioned above, there are many different variables when considering die casting projects. In solving these problems, you want to know that you are working with an aluminum casting expert who understands the ins and outs of the industry and can provide the best advice on which method is best for you.

We will work with you to take you through each of the processes listed above and describe how to best apply them to your specific needs. In addition, we are happy to answer any questions you have about the die casting process and how it works for you.

Every die casting project is different, and we treat your order with due care and individuality. Contact us now to get a free suggestion for your next custom aluminum molds project.