Aluminum Die Casting Manufacturer in China

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Die Casting

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Aluminum High Pressure Die Casting Process Overview

How does die casting work? Aluminum die casting is a metal manufacturing method that involves heating aluminum alloy to a liquid state and injecting it into custom molds under high pressure. There are six major steps of how a die-cast part&component is made:

Mold design
Casting preparation
Injection
Cooling and solidfication
Demolding / removal
CNC machining / surface treatment

Dive into the aluminum die casting processes below to get a further understanding.

Step 1

Aluminum Die Casting Mold Design

When designing the mold for your aluminum die casting project, we prioritize factors such as manufacturability and cost-efficiency. Our team provides DFM (Design for Manufacturability) support, ensuring that the mold is not only tailored to your desired part’s shape and dimensions but also optimized for efficient and cost-effective production. The mold is typically composed of two or more halves, facilitating the filling and removal process during casting.

Step 2

Casting Preparation

First, we heat the chosen aluminum alloy to its melting point while readying all necessary materials and equipment. Simultaneously, the injection machine is prepared for the molten aluminum alloy to be injected into the pre-designed mold.

Step 3

Injection

The molten aluminum alloy is then injected into the meticulously crafted mold, accompanied by the application of high pressure to ensure thorough cavity filling. After filling, a certain pressure is maintained to keep the aluminum alloy in a liquid state for a specific duration.

Step 4

Cooling and Solidification

As the aluminum alloy cools down, it solidifies and gradually takes on the desired shape within the mold. The cooling duration depends on both the aluminum alloy type and the part’s thickness.

Step 5

Demolding / Removal

Once the aluminum alloy is completely solidified, the mold is opened, and the finished parts are carefully extracted. Specialized equipment is often employed to facilitate this removal process.

Step 6

CNC Machining / Surface Treatment

Depending on specific requirements, the finished parts may undergo additional processes (CNC machining & finishing services) like cutting, drilling, or coating to meet exacting standards.

Reliable & Versatile Die-cast Aluminum for Selection

Bian Diecast takes pride in offering a diverse spectrum of top-tier die-cast aluminum alloys to cater to a wide range of industrial demands. Our carefully curated selection encompasses three primary categories, each distinguished by its unique set of properties and applications.

Common Die-cast Aluminum Alloys

Below are some of the commonly used aluminum alloy grades by our customers, known for their excellent flowability, mechanical properties, and corrosion resistance. They are frequently employed in the manufacturing of various aluminum die-cast parts.

ADC12
ADC10
DC1
A360
A380
YL102
LM6

EU Grade Aluminum Alloy Materials

These alloys offer excellent fluidity and abrasion resistance, making them suitable for manufacturing and machining various complex-shaped parts and components, including automotive components, engine housings, electronic equipment enclosures, household items, and more.

ENAC 44300(AISI12(FE))
ENAC-47100
ENAC-46000

High Thermal Conductivity Alloy Materials

These alloys exhibit excellent thermal conductivity, making them suitable for applications that require efficient heat dissipation. They find widespread use in electronics, automotive, aerospace, and other high-temperature environments.

AlSI8
LHB1

Custom Aluminum Die Casting Parts for A Wide Range of Industries

When precision and reliability matter, custom die cast parts are the go-to solution across various industries. At Bian Diecast, we specialize in crafting high-quality die casting aluminum housing components and custom die cast parts tailored to meet the unique demands of diverse sectors:

Automotive Parts >>

Die casting is widely used in the automotive sector to create components like engine and chassis parts, transmission components, electrical system parts, and body or interior/exterior parts. These components are known for their strength, durability, and precision, making them crucial for vehicle performance and safety.

Lighting Parts >>

In the lighting industry, die casting is utilized for producing components such as lamp housings, heat sinks, and reflectors. Die-cast parts offer excellent thermal conductivity, ensuring efficient heat dissipation in lighting fixtures, which is essential for their longevity and performance.

Electronics Parts >>

Die casting plays a significant role in the electronic industry by manufacturing enclosures, connectors, and heat sinks for electronic devices. These components require precise dimensions, high thermal conductivity, and electrical insulation, making die-cast parts an ideal choice.

Furniture Parts >>

Die-cast furniture parts are used in the production of chairs, tables, and various furniture pieces. These parts are appreciated for their durability, precise dimensions, and attractive surface finishes. They contribute to the aesthetics and functionality of furniture products.

Construction Parts >>

In construction, die casting provides high-quality construction hardware, including door and window hardware, furniture hardware, and stairway components. These parts must meet strict standards for dimensions and durability to ensure they integrate seamlessly into construction projects.

Cold Chamber HIGH Pressure Die Casting Capability

There are two primary methods for die casting: hot chamber die casting and cold chamber die casting. For aluminum alloy die casting, we primarily employ cold chamber pressure die casting machines, while the hot chamber method is often used for alloys like zinc due to their lower melting points.

At Bian Diecast, our factory is fully equipped with a variety of die casting machines. Each machine is capable of producing at least 2000 to 3000 die casting components per day. The largest casting area reach 3125cm².

A brief list of our high pressure die casting machines catering to different sizes of parts:

1250T Die Casting Machine	900T Die Casting Machine	800T Die Casting Machine
500T Die Casting Machine	400T Die Casting Machine	300T Die Casting Machine

Aluminum Die Casting Price

These prices indicate the cost range for producing one unit of a product using the respective die-casting machine. The actual cost within each range may vary depending on factors such as the complexity of the part, material used, and other production variables.

Die Casting Machine Model	Pricing for Reference ($ per unit)
1250T Die Casting Machine	$3-5
900T Die Casting Machine	$1.5-2
800T Die Casting Machine	$1.0-1.5
500T Die Casting Machine	$0.7-1.0
400T Die Casting Machine	$0.5-0.7
300T Die Casting Machine	$0.3-0.4

Get Aluminum Die Casting Services at One Stop!

Bian Diecast provides comprehensive assistance for your project, including mold design, die casting, CNC machining and surface finishing services. Don’t hesitate to get in touch with us!

Aluminum Die Casting Services in China

The Bian Diecast Differences

Bian Diecast, an aluminum die casting company, is located in Nanhai District, Foshan City, China. With over a decade of expertise in die casting, we are committed to providing comprehensive die casting services. Apart from specialized mold design and development, we have an advanced factory and workshops that integrate die casting, CNC precision machining, and surface finishing services, catering to diverse needs across various industries.

Currently, we have accumulated years of service experience in the automotive, lighting, electronics, furniture, and construction industries. With a solid foundation in project management, we aim to become a strategic supplier to many renowned global brands.

Project Management Excellence You Can Rely On

At Bian Diecast, efficiency & transparancy are at the core of our project mangement philosophy. Our goal is to empower our customers to closely monitor their orders while relieving them of the burdens of day-to-day project management tasks.

FAQ

What are the minimum tolerance requirements for certain precision aspects of the product? What is the minimum draft angle, and what about linear and angular tolerances?

The minimum tolerance requirements depend on the size of the product.

For dimensions up to 200mm, tolerances of ±0.1mm or better are required.

For dimensions up to 300mm, tolerances of ±0.2mm or better are necessary;

and for dimensions up to 500mm, tolerances of ±0.3mm or better are expected.

As for draft angles, a minimum of 1 degree is required, but larger angles are preferred for smoother ejection from the mold.
These tolerance specifications are essential to ensure the precision and quality of die-cast products.

What about the lifespan of your die casting mold?

50,000 shots before replacement or refurbishment. If the old die-casting mold reaches the end of its service life, we can replicate a new mold for you

What are the differences between cold chamber & hot chamber die casting? (Cold chamber die casting VS hot chamber die casting)

Cold Chamber Die Casting: This method is suitable for materials with higher melting points like aluminum and magnesium. The metal is melted in a separate furnace and then injected into the cold chamber machine. It’s ideal for casting durable and lightweight parts but can be a bit slower due to the need for metal transfer.

Hot Chamber Die Casting: Designed for materials with lower melting points, such as zinc. In this process, the metal remains in a molten state within an integrated furnace connected to the machine. Hot chamber die casting is faster and more efficient for casting smaller, intricate parts, making it cost-effective for high-volume production.

Why are your mold prices higher than those of most other factories?

Our mold prices are fair and reasonable, and we don’t aim to profit excessively from our customers on mold costs. Moreover, for customers with large order volumes, in the event that a mold becomes unusable, we offer the option of creating a new mold at no additional cost. Additionally, factors contributing to the pricing of molds include the strength and material selection in the mold design.

How do you handle sustainable practices in aluminum die casting?

Sustainability is a key consideration in our operations. We prioritize sustainable practices by minimizing waste, recycling materials, and implementing energy-efficient processes. Here at Bian, for the sake of material purity, our company utilizes a central melting furnace for the concentrated melting and refining of recycled materials before their reuse. We enforce strict control measures throughout the aluminum die casting process, including incoming raw material inspections, periodic testing of material composition every two hours, and regular third-party testing.

What certifications do you hold for quality assurance?

We hold several certifications that attest to our commitment to quality and adherence to industry standards. These certifications include ISO 9001 for quality management, ISO 14001 for environmental management, and IATF 16949, which is specific to the automotive industry. These certifications provide B2B clients with confidence in our processes and our ability to consistently deliver high-quality products.

What are the advantages of aluminum die casting?

– High precision and tight tolerances

– Efficient production of complex shapes

– Lightweight and durable

-Excellent heat dissipation

-Cost-effective for large quantities

Can you assist with design optimization for manufacturability?

Yes, our expert team provides Design for Manufacturability (DFM) services to our clients. We collaborate on designs to ensure efficient production, reducing costs and time to market.