Pressure die casting is the most widely used and the most efficient precision parts manufacturing technology. It adapts to the trends of product, like complexity, precision, light weight, energy saving and green environmental protection, in modern manufacturing. And such kind of technology is widely used in automobiles, home appliances, aviation, machinery, etc. There are 3 main die casting materials: aluminum alloy, zinc alloy and magnesium alloy.
From a global perspective, the die casting industry is a fully competitive industry. The quantity of die-casting companies in west countries is relatively small but the size of one single enterprise is large. It has strong advantage in terms of capital, technology and customer resources. Such as RYOBI Co., Ltd. in Japan, DGS company in Swiss, Kasma in Canada, Magna in Canada, George Fischer in Switzerland and so on. They have leading advantage of high-technology and high-quality for high requirement market, like automobiles and aviation. It is much ahead of most Chinese die-casting manufacturers in terms of technology and production scale.
However, China also have advantageous position in terms of market demand, raw material supply, labor resources, industrial chain support and cost. The global die casting production trend is shifting to Asia, especially mainland China and this trend continues. In recent years, China's die casting industry has maintained a steady growth of more than 10% each year.
In the past 20 years, the expansion of the market scale and the entry of outstanding international companies have promoted the improvement of the technical level and management level of domestic die casting manufacturers and further promoted the development of China die casting industry. China has formed the Yangtze River Delta, Pearl River Delta, Southwest Region and other die-casting industrial clusters. Among these industrial clusters, the Yangtze River Delta industrial cluster is the most prominent and it has formed various types of die-casting materials, various die-casting factories in various market segments, covering from batch automotive applications to low volume high mix demand, from simple requirements to precision die-casting requirements and have supporting industry chain nearby (e.g.surface treatment, heat treatment …).
There are more than 8,000 related companies in China's existing die-casting industry, which could be roughly divided into three categories:
1.Most small and medium-sized die-casting factories mainly produce ordinary die-casting products, such as hardware, lamps, toys, etc. Generally speaking, the scale of such company is small, the equipment level is low, the management level is low, the company is in a state of complete competition and so does its service level.
2.The proportion of certain scale die casting company is only about 10%. Among them, the proportion of qualified companies, who can independently serve overseas customers, is even less. These larger-scale die-casting companies have more advanced equipment and technology and could produce products that meet the requirement of high-precision die-casting products in industries, like automobiles, high-end electrical appliances, power tools and communications. Such manufacturers can establish long-term stable cooperative relations with downstream customers and they are in a more advantageous position in market competition.
3.In addition, some large foreign-funded die-casting enterprises also have set up factories in China. These enterprises have advanced technology and equipment and can produce complex precision die-casting parts. They are in a high-end position in the industry but with higher TCO cost.
Through a period of effort and based on our decades of experience, PINTUU visits lots of manufacturers and pre-assesses them, tries to identify good quality aluminum die-casting manufacturers and zinc die-casting manufacturers and will continue to develop more qualified die casting manufacturer for our clients in western countries so as to bring better supply chain services to overseas customers in following:
Reduce Time-to-Market
We support customer in developing their products at all stages from concept to mass production. Work together with die casting suppliers, providing a range of integrated technologies, processes and capabilities, including product design, process development and product validation to reduce time-to-market.
Cost-Effectiveness
We try to link customers with RIGHT die casting suppliers to achieve cost effective (by matching). Through our engineering expertise, our industry experience and knowledge will benefit our clients in the most productive way.
Customized Solutions
We provide an opportunity that is beneficial to the customers, allowing them to achieve their objectives through the application of the optimal technological solutions available.
Our supplier’s applications widely covers: automotive (Wiper system: connecting rod bracket; Engine system filter system oil pump: filter module; Air condition system: end cap mid-body; Damper system: engine bracket; Steering system: shift fork, motor housing, electric control unit; Mirror system: auto rear view modular; Braking system ABS: commercial vehicle braking system modular; Engine Lubrication System: Engine Lubrication System Modular; Auto Engine Intake Air Control System: Auto Engine Intake Air Control System Modular); Auto Transmission System: shift fork; Engine Electronic Control Unit: ECU housing; Heuristic Motor System: Heuristic Motor Housing; Engine Cooling System: Silicone oil clutch; Industrial Products: cylinder block
Actuators for Turbo Chargers; Truck Bodies; ECU Housings; Transmission Housings; Dual Clutch Systems; Power Steerings; Oil & Vacuum Pumps; RRH Outdoor Housings & Heat sinks; RF Body Filters; Black and Grey Box Solutions; RF Filters; Explore Renewable Energy; String Inverter Housings; Centralized Inverter Enclosures; Explore Energy Management; Battery Packs; Residential Storage; Grid Battery Storage, rotor.
These die casting companies not only sell products to Chinese domestic market near us, but also export certain parts to UK, USA, Europe, Germany, India and other places.
Most of our pre-assessed die casting factories have full processes from tooling design and developing, dies manufacturing, smelting (centralized or separate), high pressure die casting, low pressure die-casting, gravity die casting, trimming processing, heat treating, precision machining, surface treating, local assembling and all other processes for auto parts and other industries application.
Design, Prototyping, NPI and Validation
Using a variety of methods, most die casting suppliers act in partnership with our customers to optimize the products for manufacture. Effective collaborative design and innovative prototyping enables customers to successfully launch new products into the market.
Product engineering- Suppliers can develop die-casting tooling independently and all die-casting tools used are designed and customized according to the requirements of the customers. All the R&D personnel have professional background and have accumulated rich experience and summarized a set of advanced and efficient design concept through the long term cooperation with global well-known large multinational auto parts suppliers. In addition, the R&D personnel actively carry out simulation analysis on the flow of liquid aluminum and such impact factors by utilizing advanced technologies like computer aided design (CAD). Accordingly, mould and tooling design is optimized and improved and high-quality tooling can be trial-produced and manufactured.
Software for design and prototyping consists: Mold Flow; Solidworks; Simulation Analysis; CAD;
Mold Worksho
In house mold team adheres to scientific, rigorous and logical innovation concept through learning, digesting and absorbing advanced design theories and practices both at home and from abroad; keeps abreast of the industry's advanced technology; forms its unique advantage in the research and development of magnesium, aluminum and zinc (Zamak 3&5) alloy die casting tooling. With the core competitiveness of innovative independent intellectual property rights, the trial production and production of high quality tooling are realized and the mold team shares technology and experience with their customers.
(1)Mold team uses internationally mainstream 2D and 3D copyrighted software.
(2)Flow channel analysis uses German MAGMA casting simulation analysis software, including solution flow analysis, solidification analysis, mold temperature analysis, thermal stress analysis and die life analysis.
(3)Die-casting products have been consistently recognized by domestic and foreign partners. Mold manufacturing uses advanced imported equipment, such as five-axis machining centers, horizontal machining centers, large-scale high-speed machining centers, slow-moving wire cutters and electric sparks so as to make mold reliable and accurate.
Melting workshop
Over the years of accumulation and development, most die casting companies have core technology, including energy saving melting, automatic melting line, concentrate melting - heat preservation system and capability to produce different standard materials.
Die casting workshop
Technology development：
On the basis of mastering the core technology, independent R&D and technology innovation ability has been further enhanced through continuing cooperation for product development and technology communication. Most suppliers have developed their die casting technology in past 20 years very quickly: multistage injection with real-time feedback of controlling, high vacuum die casting, local extrusion diecasting, mold temperature controlling system, aerial fog spraying auto spray and extractors technology; flexible manufacturing, checking regression of work pieces, flexible positioning, thin-walled parts processing, knurling with cuttings, extrusion pressing and precision machining technology; integrated automation technology, like automatic loading and uploading by robots etc.; test for cleanliness, measurement for convex point surface of die casting parts, automatic detecting of X-RAY, air-leakage test, high efficient threaded-hole detecting, non-contact flatness detecting technology and such high precision detection technology.
Online management:
Except technology development, some qualified die casting companies also have very good online management system, for example, 5M1E Conceptual:
Man/Manpower - Operator's knowledge of quality, technical proficiency, physical condition, etc.;
Machine - Accuracy and maintenance status of machinery and equipment, fixtures, etc.;
Material - The composition, physical properties and chemical properties of the material;
Method - This includes processing technique, tooling options, operating procedures and etc.
Measurement - Whether the method taken during the measurement is standard and correct or not;
Environment - Temperature, humidity, lighting and cleaning conditions at the workplace;
Given extensive machining center capability, die casting manufacturers optimize their own CNC machines for different specific applications and offers the most cost effective solutions.
1.checklist：Easy to record, organize data and master problems;
2.Causal analysis：Organize the relationship between the problem and the main cause and find out the cause;
3.Plato：For a variety of questions, find out where to start;
4.Control Charts：An icon that knows if the project is in a stable state;
5.Layer method：According to the factors to distinguish the data, to understand if the "deviation" has an impact;
6.Scatter map：Understand the relationship between two pairs of data for managing the decision aspects of the method;
7.Histogram：Visualize "deviations" and use them to manage the decision aspects of the method.
Surface treatment (Sand Blasting, Powder Coating, Silkscreen, Silver Plating, Copper Plating, Nickel Plating, Selective Plating, Sand Blasting, Pad printing…)
Die casting companies also introduce surface finishing to support all other technologies and provide complete service to customers. They focus on minimizing the impact to the environment by investing in state-of-the-art waste water treatment system and reducing waste wherever possible.
Most suppliers have obtained the ISO 14001 certificate. They strive to minimize the negative impact on the environment in every aspect of the manufacturing process and continuously improve the performance of environmental management and meet green and low carbon emission principles.
Other service (assembly, welding…)
The assembly capacity allows company to deliver a total service to all of those customers looking for one stop shop, which impacts on reduced time-to-market and cost-effectiveness.
Welding, Joining Techniques, CNC FIP Gasketing, CNC Conductive FIP Gasketing
Assembly & Testing, Welding, Fiber and CO2 Robotic Laser, Resistance Welding, Spot Welding, Ultrasonic Welding, Manual and Robotic Mig/Tig Welding, Robotic Cold Metal Transfer (CMT), Joining Techniques, Tox Clinching, Tapping, Riveting, Brazing, Severing, Heat Stacking, Cold Stacking, CNC FIP Gasketing, CNC Conductive FIP Gasketing, Assembly & Testing
Quality control
Test Equipment list:
Depending on diverse applications, the establishment of in house test equipment is the must. So do several types of analysis instruments, in line with customers’ requirements, to inspect all kinds of die casting components and assemblies accurately.
Mechanical property tester
CT detection equipment
X-ray detector
3D scanner
CMM
Spectrum analyzer
Chemical composition
Part & Coating X-RAY
Metallographic microscope analyzer
Hardness tester
Quality control system:
All qualified companies carry out full participation and full coverage of quality management system pursuant to the quality controlling standards of IATF16949. 5 major tools are widely applied in the key points of the component quality controlling:
APQP Advanced product quality planning
PPAP Production part approval process
FMRA Analysis of potential failure modes and their consequences
MSA Measurement system analysis
SPC Statistical process control
