Custom Die Casting from EATHU

30th October, 2024

Custom die casting services provide a reliable and efficient way to produce high-quality metal components. With the ability to accommodate complex designs and achieve high precision, die casting is a preferred choice for manufacturers looking to enhance their production capabilities while meeting the demands of diverse industries. Whether you're looking for prototyping or large-scale production, custom die casting can be tailored to fit your specific needs.

 

What Is Custom Die Casting?

Die casting is the preferred manufacturing method for producing high volumes of relatively complex metal parts, valued for its versatility, reliability, and precision. This process significantly reduces or eliminates the need for secondary operations typically required to finish a metal part; however, post-machining is often utilized to achieve tighter critical-to-function tolerances. Additionally, die cast components can be post-processed with the same finishes available for their CNC machined equivalents.

 

Similar to injection molding, die casting necessitates the creation of a mold tool, known as a die, which can have one or multiple cavities. It is particularly effective for softer alloys, such as aluminum and zinc, due to their lower melting points. The process involves injecting molten metal into the die cavity, where it takes the shape of the desired part and solidifies before removal. Depending on the project requirements, die casting can be performed using low or high pressure, with metal deposited via ladle or plunger. This method can produce highly intricate, tight-tolerance parts consistently at very high production volumes. Advanced die casting techniques, such as squeeze casting and semi-solid metal casting, yield high-quality components suitable for nearly all industries. Most die casting companies specialize in either aluminum or zinc, with aluminum accounting for about 80% of die cast parts.

 

Die Casting Types

EATHU collaborates with die casters that use the latest machines and technology to provide high-quality, on-demand parts across various industries. Our services emphasize the two primary types of die casting: hot chamber casting and cold chamber casting. Both methods are capable of producing parts with intricate geometries, tight tolerances, and strong mechanical properties.

 

Hot Chamber Die Casting

Hot chamber die casting is a manufacturing process used primarily for producing parts from low-melting-point alloys, such as zinc, lead, and magnesium. In this method, the die casting machine features a heated chamber that holds molten metal. A mechanism known as a gooseneck injects the molten metal into the die under high pressure.

 

The main advantage of hot chamber die casting lies in its efficiency and speed. Since the molten metal is readily available in the chamber, the cycle time is reduced, allowing for rapid production rates. The process is particularly suitable for parts with complex geometries and fine details, as the high pressure helps fill intricate molds effectively.

 

However, hot chamber die casting is limited to metals with lower melting points due to the design of the equipment. This method is widely used in industries such as automotive and consumer goods, where precision and speed are essential. Overall, hot chamber die casting offers an effective solution for producing high-quality parts quickly and reliably.

 

Cold Chamber Die Casting

Cold chamber die casting is a manufacturing process typically used for producing parts from high-melting-point alloys, such as aluminum and copper. In this method, the molten metal is poured into a separate chamber before being injected into the die. The chamber is not heated, which is a key distinction from hot chamber die casting.

 

During the process, a mechanism known as a piston pushes the molten metal from the cold chamber into the die under high pressure. This method allows for greater control over the metal being used, making it suitable for alloys that would otherwise be problematic in a hot chamber setup.

 

Cold chamber die casting is particularly effective for creating parts with complex shapes and tight tolerances. It is widely employed in industries such as aerospace, automotive, and electronics, where high-quality and durable components are crucial. Although the cycle times may be slightly longer than those of hot chamber die casting, the ability to work with a broader range of materials makes cold chamber die casting a valuable technique in precision manufacturing.

 

Die Cast Metal Materials

There are various metal materials available for die casting, and the choice of material will depend on the intended application of the product. For example, cast aluminum parts are frequently used in aerospace and automotive industries due to their corrosion resistance and lightweight properties. You can find more information about the primary types of die casting materials we provide in the sections below. If you have a specific material in mind, please let us know!

 

Aluminum Die Casting

Aluminum die casting is a manufacturing process that involves injecting molten aluminum into a mold, or die, to create precise and complex parts. This method is widely used due to aluminum's favorable properties, including its lightweight nature, excellent corrosion resistance, and good mechanical strength. The process typically involves either hot chamber or cold chamber die casting, with cold chamber being more common for aluminum due to its higher melting point.

 

During the process, aluminum is melted in a furnace and then injected into the die under high pressure, ensuring that the metal fills every detail of the mold. Once the aluminum cools and solidifies, the die is opened, and the finished part is ejected. This technique allows for high production rates and the ability to produce intricate designs with tight tolerances.

 

Aluminum die casting is particularly popular in industries such as automotive, aerospace, and consumer electronics, where the combination of light weight and durability is critical. Additionally, aluminum die cast parts can undergo various post-processing treatments, such as machining, coating, or plating, to enhance their functionality and appearance. Overall, aluminum die casting is an effective method for producing high-quality components that meet demanding specifications.

 

Zinc Die Casting

Zinc die casting is a manufacturing process that involves injecting molten zinc into a mold, or die, to create detailed and precise components. This method is favored for its ability to produce parts with excellent dimensional accuracy and surface finish, making it suitable for a variety of applications. Zinc has a relatively low melting point, which allows for efficient casting and rapid production cycles.

 

The process typically uses a cold chamber die casting technique, where molten zinc is poured into a chamber and then forced into the die under high pressure. This ensures that the metal fills the intricate cavities of the mold, resulting in complex shapes with tight tolerances. Once the zinc solidifies, the die is opened, and the finished part is ejected.

 

Zinc die casting is particularly popular in industries such as automotive, electronics, and hardware due to the metal's strong mechanical properties and corrosion resistance. The parts produced are not only lightweight but also durable, making them ideal for both functional and aesthetic applications. Additionally, zinc components can be easily plated or coated for enhanced appearance and protection. Overall, zinc die casting is an effective method for producing high-quality parts that meet rigorous industry standards.

 

EATHU Die Casting Service

Our project managers and experts conduct personal reviews and manual quotes for each die casting project to ensure we meet your specific requirements while delivering a quick and seamless manufacturing experience. Explore more about our process and capabilities in the sections below.

 

Start A Quote

Upload your files to our website and set up your project. Our team will work with you to confirm that your specifications, lead time, and pricing align with your project requirements. We will also provide a Design for Manufacturability (DFM) report for your approval before starting the tooling process.

 

Sample Approval

Once your project is initiated, we will create a high-quality die. After the tooling is completed, we will send out part samples for your approval.

 

Production Begins

Once you're satisfied with the samples, we will proceed with production and deliver the parts. You can relax knowing that EATHU is managing supplier relations and logistics throughout the entire process. You retain ownership of your tooling and can easily reorder as needed to meet demand.

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