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design die casting tool for medium and high-volume manufacturing
Premium Parts offers a complete range of high-grade pressure die casting services for low-volume and mass production of metal parts. Our services accommodate varying applications, including part casting, mold tool making, post-production machining, and finishing services that complete your parts.
Our die casting solutions can work with a range of metal alloys to ensure that your project is well-tailored to your desired end uses. We make parts with excellent dimensional accuracy, tight tolerances, and thin walls, where specified. From aluminum to magnesium and zinc, our casting machines, along with durable, detail-arresting molds, are our unique value propositions that ensure that we deliver parts of the highest standards and quality.
At Premium Parts, we can use our die casting services to lower the cost per unit part. We can make steel molds through rapid tooling to accommodate budgetary constraints when dealing with low-volume production runs. From wet painting and powder coating to polishing and anodizing, and more, our premium finishing solutions will augment your parts' overall appearance and cosmetics.
What is Pressure Die Casting
Pressure die casting is a metal low-volume and mass-production technique. Pressure die casting service involves injecting molten metal into a mold cavity or steel die under high pressure to produce strong, functional, and trustworthy parts that match design specifications. The process is similar to injection molding and is a guaranteed method of making average to substantial volumes of metal parts. The high pressure involved in the process is essential to ensure that all the mold details are arrested on the casted parts. Premium Parts employs state-of-the-art machines and high-quality pressure casting dies to produce parts with excellent surface finish, tight tolerances, and inch-perfect dimensional precision. With varied and extensive experience in die casting, our process is dynamic, practical, and cost-effective. Choose from zinc, aluminum, magnesium to accommodate your material, end-use, and volume needs.
At Premium Parts, we run several die casting processes. Our pressure die casting operations may be summarized as hot-chamber or cold-chamber die casting. The hot-chamber die casting process is suitable for casting metal alloys with low melting points and high fluidity. The cold-chamber process is reserved for metals with higher melting temperatures. Cold-chamber processes are frequently used with aluminum, magnesium, and brass, while zinc, magnesium, copper are all cast in hot-chamber processes.
Our pressure die casting process consists of 6 steps. Die-casted parts are manufactured in steel molds similar to those used in injection molding under high pressure and cooled to set into the shape of the casting. Our Premium die casting manufacturing process can be summarized as follows:
1. Clamping
Here, the dies are cleaned and lubricated. The die halves are then closed and clamped under high pressure.
2. Injection
During the injection phase, the molten metal is injected and forced into the clamped die under extremely high pressure. The molten metal is kept in the die until it solidifies.
3. Cooling
The molten metal, now in the die, is cooled. This process is essential to allow the solidification of the metal. The cooled metal fully forms the part and takes the shape of the casting.
4. Ejection
Once the metal has cooled, the ejection process begins. Here, the die halves are unclamped, and the solidified part is pushed out of the die.
5. Trimming
This process is a pre-finishing process that ensures removing excess metals in the sprue and runner along with any splash or metal debris. These extra materials are removed from the final die-casted product to ensure cleanliness, dimensional, and physical accuracy.
6. Finishing services (Optional)
After completing the die-casting process, we offer high-quality finishing services ranging from polishing, plating, painting, sandblasting, and powder coating.
Why You Should Use Pressure Die Casting
• Cost per part
Die casting is the most economical method of producing large volumes of metal parts with high quality. Die casting will usually have a lower cost-per-part than other metal production techniques.
• Complex features
Die casting can achieve complex parts and incorporate certain features into the mold design to reduce the need for assembly and joining.
• Dimensional accuracy
Die casted parts have excellent dimensional accuracy and stability. Because of the high pressure involved, parts are made to replicate the mold tool's exact specifications.
• Finishing options
The surface finish and cosmetic appearance of castings can range from smooth to textured as required. Castings can be anodized, painted, or polished to give the desired aesthetics.
• Speed
Once the tooling design is concluded, and the mold tool is produced, the die casting cycle time itself is very fast. The average die casting cycle spans between 3 to 60 seconds, making it one of the quickest production techniques.
• Tool life
Because die casting is often used for mass production runs, the mold tooling is usually made from hardened engineering-grade steel. Die casting tools can make up to tens of thousands of parts before wear and tear begin. This makes it an excellent investment.
Die casting can make large parts and even larger volumes of parts. The process is mostly applied to mass production operations where cost can be spread over more volume, and the cost per part is relatively reduced. This is one of the reasons why die casting operations can help improve the profitability of your parts.
Premium Parts pressure die casting operations can be used in any of the following industries:
• Aerospace
• Energy and power
• Industrial
• Automotive
• Consumer products
• Construction
• Robotics
• Aluminum
Aluminum has low weight, high strength, and high castability. It has excellent thermal and electrical conductivity and can be finished in an array of ways. Aluminum castings are naturally corrosion-resistant.
• Zinc
Zinc is very ductile with high density. It is widespread, affordable, and has the easiest castability. Zinc is prone to corrosion and must be coated to manage the chances of rusting. Zinc castings boast good impact resistance and surface characteristics.
• Magnesium
Magnesium has a very good strength-to-weight ratio. It is also easily machined and well suited to the rigor of high-performance applications.
• Copper
Copper is used for its electrical conductivity, high strength, and dimensional stability. While the material may be a little pricey, it has excellent wear and tears resistance.
At Premium Parts, our metal castings can be subjected to several finishing solutions to bring the best out of your parts cosmetically and performance-wise. Some of our finishing techniques for pressure die casting include:
• Standard
• Sandblasting
• Sanding
• Painting
• Powder coating
• Plating
• Polishing
• CNC machining
• Anodizing
Our competitive advantages in each manufacturing solution that we offer are what sets us apart from others. Our pressure die casting solutions have been optimized to produce the best parts that match our clients' high-performance needs. Here are some of the reasons you should choose Premium Parts pressure die casting solutions:
Premium Parts uses experience and capacity to bring you the best die-casted parts. We take every step seriously before delivery, and run every production process, from raw material sourcing to finishing, through our quality control systems.
• Cost and Profitability
Premium Parts adds value to our client's businesses by exploring ways to deliver your parts at a lower cost-per-part to help you drive your profitability and business margins. Premium Parts is one of the most competitive manufacturing businesses in China.
We will optimize our pressure die casting services to help you get to your target audience quicker. Our in-house capacity also helps us make tooling faster, shorten casting cycles, and land products quicker.
Premium Parts can handle your entire product development cycles from design to prototypes and the final part. Our one-stop-shop services also cover your product development from raw material screening to casting and finishing solutions that enhance your parts' appearance and functionality.
Choose Premium Parts pressure die casting services and accelerate your metal manufacturing orders right away. With our vast experience and machining capabilities, our die casting solutions are your best option for making quality end-use parts with excellent finish and dependable quality.
1. When can I receive the DFM for my part?
We can offer the DFM free of cost with quote sending.
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