Custom Die Casting
In the ever-evolving world of manufacturing, the choice of a reliable partner for your aluminum die casting needs is pivotal. XDL Machinery proudly presents its top-tier Aluminum Die Casting Service.
Key Capabilities
1. ISO 9001 & IATF 16949 Certifications
We are committed to delivering the highest standards of quality in all our die casting products and services. To ensure consistent excellence, all our key partners hold globally recognized certifications, including ISO 9001 and IATF 16949.
2. Die Design and Manufacturing
Advanced Die Design and Mold Flow Analysis
We employ advanced mold design techniques combined with mold flow analysis to ensure optimal performance and efficiency of every die we produce. By simulating the casting process, we identify potential flow issues, air entrapment, and hot spots before production begins, ensuring the best possible die design for achieving high-quality castings with minimal defects.
Premium Mold Steel and Heat Treatment Expertise
The quality of our dies begins with the material. We source high-quality mold steels from trusted suppliers, ensuring the durability and longevity of every die we manufacture. Additionally, we have an in-house heat treatment facility that allows us to fine-tune the hardness and wear resistance of the dies to suit the specific needs of the casting process, ensuring consistent and reliable performance.
State-of-the-Art Die Manufacturing Equipment
Our state-of-the-art machining and die manufacturing equipment enables us to produce complex, high-precision dies efficiently. With cutting-edge CNC machining centers and EDM (Electrical Discharge Machining), we achieve tight tolerances and high surface finishes, essential for producing high-quality cast parts. This equipment, combined with our expert team, ensures we can meet the most demanding die casting requirements.
Rigorous Inspection and Quality Control
At XDL Machinery, quality is our top priority. Every die we manufacture undergoes strict quality control inspections, including precise measurements with CMM (Coordinate Measuring Machines) to ensure dimensional accuracy and conformity to design specifications. This rigorous inspection process guarantees that all dies meet the highest standards, providing our clients with dependable tools for producing flawless die-cast parts.
3. Mold and Alloy Materials Quality Control
We understand that the choice of mold materials and alloy materials plays a crucial role in determining the quality, durability, and performance of the die-cast parts. To ensure superior quality and long-term performance, we source only the best materials and adhere to strict quality control protocols.
The alloy materials we offer are suitable for different die casting applications, including:
Aluminum Alloys (e.g., A380, A360, A413): Known for their lightweight, excellent corrosion resistance, and ease of machining, aluminum alloys are widely used in die casting for automotive, electronics, and industrial parts.
Zinc Alloys (e.g., ZA-8, ZA-12, Zamak): Zinc alloys are ideal for high-strength, precision components with excellent surface finishes, commonly used in electrical connectors, automotive parts, and household products.
4. Casting Capability
we have the capability to produce a wide range of die-cast products, from small, precision components to large, heavy-duty parts. Our flexible and highly efficient casting process allows us to cater to diverse client needs across various industries.
Range of Product Sizes
We specialize in manufacturing die-cast products in a broad weight range, ensuring we can meet the specific needs of our customers:
Small Parts: We can produce die-cast components as small as a few grams. These small, high-precision parts are ideal for industries such as electronics, automotive, and consumer products, where detailed and accurate components are essential.
Large Parts: Our capabilities extend to producing larger, heavier die-cast parts, with a maximum weight of up to 10 kilograms. These larger components are commonly used in industrial machinery, automotive, and material handling equipment, where strength, durability, and precision are critical.
Advanced Die Casting Process
Our state-of-the-art die casting machines and processes enable us to manufacture products with high accuracy and excellent surface finishes. Whether you’re looking for small, intricate parts or large, heavy-duty components, we ensure consistent quality and dimensional precision across the entire production range.
5. CNC Machining Capabilities
We offer precision CNC machining services to ensure that every die-cast part meets the highest standards of accuracy and quality, with tolerances as tight as 0.01mm. Our advanced machining capabilities are designed to handle complex geometries, providing consistent precision for a wide range of applications.
High Precision and Tight Tolerances
We specialize in CNC machining with extremely tight tolerances, achieving precision down to 0.01mm. This level of accuracy is critical for manufacturing parts that meet the most demanding specifications, ensuring both functionality and fit.
Advanced Multi-Axis Drilling and Tapping
Our facility is equipped with multiple high-precision multi-axis drilling and tapping machines, which allow us to efficiently produce parts with complex features such as multi-surface holes and threaded sections. These machines ensure stable quality and high production capacity, allowing us to meet both large volume and detailed requirements with consistency and speed.
6. Comprehensive Surface Treatment Options
We offer a wide range of surface treatment options to enhance the appearance, durability, and performance of our die-cast products. Our surface treatment services are designed to meet the specific needs of our clients across various industries, ensuring that each part is finished to the highest standards.
Comprehensive Surface Treatment Options
We provide the following surface treatment processes:
- Pickling
- Passivation
- Vibratory Finishing
- Drying
- Powder Coating
- Sandblasting
- Baking and Curing
- Anodizing
- Oil Spraying
- Electroplating
- Electrophoretic Coating (Electrophoresis)
Quality Assurance in Surface Treatment
We ensure that all parts undergo rigorous quality checks throughout the surface treatment process to meet your specific requirements. Whether it’s for aesthetic purposes, corrosion resistance, or durability, our surface treatment capabilities are designed to give your die-cast products a high-quality finish that enhances their performance and longevity.
7. Comprehensive Product Inspection
Quality control is at the heart of our production process. We adhere to strict process controls throughout manufacturing to ensure every part meets the highest standards. To guarantee product excellence, we implement 100% final inspection on all products before shipment, following the principle of “No defective products reach the customer.”
Comprehensive Product Inspection
Our inspection process includes both dimensional and visual inspections using specialized gauges and instruments to ensure precise measurements and flawless appearance. Every part undergoes a thorough check to ensure it meets the required specifications and quality standards.
Dimensional Inspection: We use precise measuring tools, including CMM (Coordinate Measuring Machines), to ensure that all critical dimensions are within the specified tolerances.
Visual Inspection: All products are visually inspected for surface defects, cracks, or any signs of imperfections, ensuring they meet our aesthetic standards.
See details of our Quality Assurance procedure.
8. Packaging and Shipping
Once products pass inspection, they are carefully packaged to ensure they remain protected during transit. We use high-quality packaging materials designed to prevent damage and maintain the integrity of the parts, regardless of size or complexity.
gallery of our aluminum die casting parts
Quality Assurance
Advanced Measurement Systems
At XDL Machinery, we are committed to delivering die-cast components that meet the highest standards of quality and precision. Our comprehensive Quality Assurance program ensures that every product we manufacture undergoes rigorous testing and inspection, utilizing advanced technologies and industry-leading equipment.
ISO 9001 and IATF 16949 Certified Processes
Our injection molding operations are certified under ISO 9001 or IATF 16949, ensuring that we follow globally recognized quality management standards. These certifications demonstrate our commitment to maintaining consistent quality, improving processes, and meeting industry-specific requirements, particularly for automotive, electronics, and packaging applications.
Advanced Measurement Systems
We employ a range of sophisticated tools to precisely measure the dimensions and physical characteristics of every component:
CMM (Coordinate Measuring Machine): Our CMMs provide precise, automated 3D measurements, ensuring the exact dimensions of complex parts are consistently met.
Vision Measuring Systems: These systems use high-resolution cameras and image analysis software to perform detailed inspections of component features, ensuring they meet design specifications with high accuracy.
Handheld Measurement Tools: For more specific measurements, we use high-precision tools such as:
- Vernier Calipers: For measuring external and internal dimensions with fine precision.
- Height Gauges: For vertical measurement accuracy, ensuring uniformity and consistency in component dimensions.
- Micrometers: For precise internal diameter measurements, particularly for intricate hollow components.
- Go/No-Go Gauges : To check whether parts conform to specific tolerance levels, ensuring they fit seamlessly in their intended applications.
Material Testing and Alloy Analysis
To ensure the durability and performance of our die-cast parts, we carry out extensive material testing:
Spectrometers: Our spectrometers are used to analyze the chemical composition of alloys, verifying the material properties and ensuring that each batch conforms to the required standards for strength, corrosion resistance, and other vital characteristics.
Chemical and Mechanical Testing Instruments: We also use specialized equipment to assess the mechanical properties of alloys, such as tensile strength, hardness, and fatigue resistance. This ensures that all parts can withstand the rigorous conditions they are designed for.
Additional Testing Services
In addition to dimensional and material testing, we offer other critical testing services to meet our clients’ needs:
Leak Testing: We conduct airtightness tests to ensure that components, especially those used in fluid or gas systems, are completely leak-proof.
Coating Thickness Testing: For parts that require protective coatings (such as anodizing or painting), we measure the thickness of coatings to ensure uniformity and effectiveness in protecting against corrosion and wear.
Materials
Materials Used in Precision Injection Molding
we specialize in die casting using a variety of aluminum alloys and zinc alloys, which are widely used in industries ranging from automotive to consumer electronics. These materials are chosen for their excellent casting properties, durability, and versatility, ensuring high-quality results in every product.
Aluminum Alloys
We work with several grades of aluminum alloys that offer excellent strength-to-weight ratios, corrosion resistance, and thermal conductivity. Commonly used grades include:
- A380: Widely used for automotive and industrial parts due to its good fluidity, excellent casting properties, and overall strength.
- A360: Known for its excellent corrosion resistance and better machinability, often used in high-performance parts like housings and pump bodies.
- A413: Ideal for producing thin-walled castings with high integrity and strength, commonly used for parts requiring high precision.
- A356: Often used in applications requiring high strength and good corrosion resistance, such as in aerospace and marine industries.
- ADC12: A widely used alloy for its good fluidity and high-strength characteristics, making it ideal for automotive and electrical applications.
Zinc Alloys
- Zinc alloys offer excellent castability, high corrosion resistance, and ease of machining, making them a preferred choice for precision parts. Common zinc alloys include:
- Zamak 3 (ZA-3): The most commonly used zinc die casting alloy, known for its strength, durability, and excellent dimensional stability. It’s used in a wide range of applications including automotive, hardware, and consumer products.
- Zamak 5 (ZA-5): Known for superior strength and higher resistance to creep, making it ideal for applications requiring better mechanical performance.
- Zamak 8 (ZA-8): Offers a balance of strength, stability, and corrosion resistance, often used in electrical components and small precision parts.
- Zinc 2 (ZP2): Provides higher tensile strength and is used in heavy-duty die casting applications such as engine parts and industrial machinery.
General Processes for Die Casting
1. Die Design and Manufacuturing
2. Melting the metal
3. Ejection
4. Trimming
5. Heat Treatment
6. Machining
7. Inspection
8. Packaging and Shipping
Industries We Serve
- XDL Machinery’s plastic injection molding services support a broad range of industries, providing high-performance components tailored to meet the specific needs and applications of each sector:
- Electronic Motor Components
- Automotive Components
- Industrial Equipment
- Telecommunication Equipment
- Home Appliances
FAQs: Your Queries Answered
We offer a wide range of die casting services, including aluminum, zinc, and magnesium die casting, as well as precision casting for industries such as automotive, motors, telecommunications, and home appliances. We also provide additional services like CNC machining, surface finishing, and assembly.
Our typical lead time for die casting production ranges from X to Y weeks, depending on the complexity of the part, mold preparation time, and order volume. For urgent orders, we offer expedited services, but please discuss your timeline requirements with us in advance.
Yes, we specialize in producing custom die-cast parts based on client specifications. We can also produce prototypes for testing purposes. Using advanced CAD software and 3D modeling, we ensure the design matches your exact requirements before proceeding to production.
We have extensive experience serving various industries, including:
- Automotive (engine parts, transmission components, chassis parts)
- Electronics & Telecommunications (mobile phone housings, networking equipment)
- Motors (motor housings, end shields, rotor components)
- Home Appliances (refrigerator parts, washing machine components)
- And more.
We use a combination of advanced quality control methods to ensure product accuracy and durability. This includes:
- Coordinate Measuring Machines (CMM) for precise dimensional measurement.
- Vision Measuring Systems for visual inspections.
- Spectrometers for alloy composition analysis.
- Mechanical testing for tensile strength, hardness, and fatigue resistance. We also perform additional tests such as leak testing and coating thickness testing based on customer requirements.
