In the die casting world, aluminum is the most widely used metal. It is known for its lightweight nature and high strength-to-weight ratio. Customized aluminum die casting parts are commonly used in many industries. It is one of the most popular manufacturing businesses nowadays.

Many industries typically need these customized aluminum die casting parts. You will find their uses in automotive, electronics, medical, and consumer products. The die casting method enables the creation of complex shapes, which can be challenging to achieve through other processes. The technique also ensures high efficiency and excellent surface finishes.

In recent years, custom aluminum die casting has gained popularity. Companies no longer want to use standard shapes. They want solutions designed for their specific applications. Here, custom molds and customized aluminum die casting parts are available for use.

Custom aluminum die casting enables the design of unique parts for various applications. Whether you are looking for auto parts or electronics housing, this is the method you should follow. It not only reduces costs but also ensures high strength.

This article primarily covers the topic of custom aluminum die casting. We will cover the process, products, alloys, and advantages. You will also learn how to choose the proper manufacturer and why aluminum is the best choice for die casting.

What is Aluminum Die Casting

Aluminum die casting is a process that converts molten aluminum into the desired shape and form. Typically, the molten aluminum is subjected to high pressure in a mold, also known as a die. The method is highly efficient for large-scale production. Components with intricate designs or shapes can be achieved easily. There is no need for extra steps. It means that every customized aluminum die casting parts face the same consequences and undergoes the same steps.

In this process, customized aluminum die casting parts come out with excellent dimensional accuracy. This way, it minimizes the additional finishing touches. Why do people opt for this method? Although it is lightweight, it produces strong and durable parts that are suitable for industrial use.

Introducing Custom Aluminum Die Casting

Custom aluminum die casting is similar to standard die casting methods. However, what makes this process different is the involvement of custom designing, testing, and validation.

Custom aluminum die casting becomes necessary when unique strength, precision, and durability are necessary. Also, it is ideal for both small and large production runs.

One of the primary applications of custom aluminum die casting is evident in the automotive industry. Many car parts are manufactured in this manner. Additionally, many military and telecommunication projects require a custom die casting process to meet their unique needs. Even consumer business heavily depends on this manufacturing method.

Process of Custom Aluminum Die Casting Parts

Customized aluminum die casting parts go through a similar customization process to other alloys. At Aludiecast, we take the requirements from the customer. Then, we analyze it and prepare the manufacturing steps. Finally, we test it and deliver it to the right destination. If we expand the entire manufacturing process, it can be broken down into the following nine steps.

Step #1: Design Discussion & Requirement Analysis

The process begins with a detailed discussion with the customer. At Aludiecast, we collect all the specifications and understand the purpose of the part. The requirement list typically includes the size, shape, tolerances, surface roughness, and strength needs.

You may also provide drawings or 3D models, if available, which would be beneficial. If not, our design team typically prepares the models for visualization. At this stage, it is essential to clarify every detail before proceeding. Therefore, good communication is crucial. You must choose a manufacturer that has a reliable customer support team. Your agent must understand what you want. They must accurately deliver your requirements to the internal teams.

The design stage also considers the feasibility of manufacturing. Engineers typically review whether the design can be cast efficiently. Above all, this step ensures that the project starts on a clear and solid foundation.

Step #2: Prototype Development

Before making the expensive die-casting mold, creating the prototype is a crucial step. This prototype typically comes through other methods rather than die casting. In this case, plastics, resin, or CNC-machined aluminum are some typical materials. The purpose of making the prototype is to test the design in its real form. You can check the product’s size, appearance, and ergonomics.

The prototype also helps engineers check assembly fit with other parts. It is a cost-saving stage because changes are easier here. If any adjustments are needed, we will update the design before mold development.

Once the prototype is approved, we can confidently move to the next stage. This way, you can reduce risks and save time.

Step #3: Mold Design & Simulation

After the prototype is approved, we begin designing the die-casting mold. A mold is the most crucial part of the die casting. It defines the final shape and accuracy of the product. Before creating the mold, engineers typically simulate and test the mold virtually. It is essential to observe how aluminum will flow inside the mold.

During the test, they also check for possible problems, like shrinkage, bubbles, or cracks. By running simulations, we can predict issues before they happen. The design is then adjusted for efficiency and durability.

Step #4: Mold Manufacturing

Una volta che il mold design is approved, the manufacturing of the mold begins. Based on the complexity of the mold, various methods are used. We may need tools such as CNC machines or EDM equipment. At Aludiecast, we shape each part according to the approved design.

The mold parts may require additional heat treatment to enhance their hardness and durability. The mold must withstand high pressure and temperature during the casting process.

After machining, the mold undergoes a thorough inspection. Every dimension is checked to confirm accuracy. Minor errors at this stage may cause significant issues in production. Only after passing the check is the mold approved for die casting production.

Step 5: Die Casting Production

With the mold ready, we move to the die casting stage. Here, molten aluminum is injected into the mold at high pressure. The metal quickly fills the mold and takes its shape. Cooling happens within seconds, and the mold is opened.

The mold can be opened either with an ejection pin or through a controlled program. Automated ones typically do the whole work automatically. It requires no manual operations.

This stage is a repeatable process that creates similar parts repeatedly. Some examples include customized OEM die cast aluminum boxes, antenna housings, or automotive parts. At this stage, you can develop hundreds or thousands of parts in a short time.

Step #6: Post-Processing & Machining

After casting, parts are not yet complete. They still require some additional work to achieve a smooth surface. At this stage, we apply various machining techniques based on the final product’s shape. The extra material from the die-cast part is removed. If necessary, we also drill holes, cut threads, or create blind holes.

Surface finishing, on the other hand, improves appearance and durability. You can choose the type of surface finishing. Some typical finishing techniques include powder coating, anodizing, painting, and polishing. These finishes protect against corrosion and enhance the product’s overall appearance.

Post-processing typically ensures that each part aligns with your project’s needs. This step is flexible depending on the final parts.

Step #7: Quality Inspection

Every customized aluminum die casting part then undergoes strict quality checks. This step may involve measuring the sizes, checking for any defects, scratches, or bubbles. Mechanical testing may include strength, hardness, or pressure resistance. For critical parts, X-ray or CMM checks are ideal to see internal quality.

The goal is to confirm that every part matches your expectations. We do not ship any product until it passes inspection. This step typically guarantees that the customized pressofusione di alluminio parts we produce are reliable.

Step #8: Assembly (Optional)

Sometimes, a few customers also request the complete assembly of customized aluminum die casting parts. For example, a die-cast aluminum enclosure customized wholesale may include upper and lower housings. Alternatively, aluminum die-casting components for a dental chair factory may be combined with other parts.

Assembly saves you time and provides ready-to-use solutions. Depending on your project needs, we may use screws, welding, or adhesive for the work. Once assembly is complete, we retest the final product to ensure its quality. This way, we can ensure smooth operation and long-term durability of the customized aluminum die casting parts.

Step #9: Packaging & Shipping

The final step is packaging and shipping. Before shipping, it is necessary to clean and prepare the parts. At Aludiecasting factory, we always ensure that protective packaging is used to prevent damage during transport. Bubble wrap, foam, or custom boxes are some typical ways of protection.

Additionally, proper labeling is essential for accurate identification and tracking. Once everything is ready, your product will be shipped via air freight or sea freight. Your preferences typically decide the type of shipping.

Products and Applications of Custom Aluminum Die Casting

Many industries require customized aluminum die casting parts. Their strength, lightweight, and precision make them ideal for many critical applications. Popular use cases are electronic housing, medical equipment, automotive parts, and daily consumer goods.

Die Casting Aluminum Enclosure Customized Wholesale

Die-cast aluminum enclosures are everywhere. Examples include customized OEM die cast aluminum boxes, LED drivers, battery systems, engine units, and other similar components. Its material-wide efficiency is the reason why people opt for it. Due to this, it can be an ideal choice for producing high-volume, durable, and long-lasting parts.

Aluminum Die Casting Dental Chair Custom Factory

Custom tools that are very accurate and made to exact specs are crucial in the medical field. This is why manufacturers use metal die-casting to produce dental chairs, hospital beds, and surgical tools. It has a wide range of applications in this field for making customized aluminum die casting parts.

Parti di ricambio per autoveicoli

In the automotive sector, the lightweight and stable nature matters more. For this reason, people utilize aluminum alloy to produce engine blocks, transmission housings, and various brackets. You can also make complex shapes that are crucial for modern vehicles.

Prodotti di consumo

Aluminum is one of the most used metals in consumer goods. Phone or laptop casings, washing machines, and microwave parts are some examples. Others include cameras, audio systems, and household appliances.

Aluminum Alloys Used in Custom Die Casting

In customized aluminum die casting parts manufacturing, we typically use various types of aluminum alloys. Each alloy has its unique benefits and applications. In most cases, customers usually decide on the exact kind of alloy. The following are the most commonly used aluminum alloys in the manufacture of customized aluminum die casting parts.

ADC12 Aluminum Alloy

ADC 12 is one of the most widely used aluminum die casting alloys. The alloy is a mixture of aluminum (8.5–9.5%), silicone (0.7–1.3%), iron (0.35%), and many other elements. The alloy offers balanced mechanical properties and is cost-effective.

Lega di alluminio A380

A380 is the most common and versatile alloy in the North American region. It combines 8.5–9.5% aluminum and 3.0–4.0% copper with other elements. With a tensile strength of 325 MPa, it has a wide range of applications in various sectors.

AlSi9Cu3 or EN AC-46000

AlSi9Cu3 alloy is quite similar to the A380 and has superior casting features. Moreover, it has high fluidity, making it suitable for thin-walled parts. Although the alloy has low ductility, it can withstand temperatures up to 200 °C.

ADC 10 Aluminum Alloy

ADC 10 shares some common features with ADC12, but offers improved ductility. It is often used in particular cases when parts need to be bent or formed after casting. Such features make it suitable for specific housings and brackets.

AlSi12 or EN AC-44100

AlSi12 is also a popular alloy known for its fluidity and resistance to oxidation. Here, EN AC-44100 shows the European numeric system designation of the alloy. It has moderate strength and good machinability, and is heavily used in textile machinery parts.

Lega di alluminio A360

A360 aluminum alloy is a typical alloy with excellent fatigue strength. It has a typical tensile strength of 317 MPa and a minimum elongation of 3.5%. However, the key characteristics include 9.0–10.0% silicon, which eventually lowers the melting point.

Lega di alluminio A383

A383 Aluminum Alloy contains 8.5–9.5% silicone with higher hardness strength. It’s a modified version of the A380 with a melting point of around 549 ℃. It could be a good alternative to the A380 aluminum alloy.

A390 Aluminum Alloy

The A390 aluminum alloy is a high-content silicon mixed alloy (16–18%). It is ideal for friction-prone sections due to its strong wear resistance, such as engine pistons and cylinder liners. However, it is less ductile and more rigid to cast.

Lega di alluminio A413

A413 Aluminum Alloy is also known for its high fluidity and tightness. The alloy is suitable for making thin-walled parts in the automotive sector. Its high silicon content (11-13%) provides good wear and corrosion resistance.

EN AC-47100

This alloy is another European equivalent to A383, offering similar benefits. It’s used for parts that are very complicated and likely to tear when heated. Additionally, the alloy has excellent durability and castability.

Advantages of Custom Aluminum Die Casting

You may wonder why die casting is used instead of other methods, such as Lavorazione CNC or EDM. Even if it is a metal casting process, why not consider other methods, such as investment casting or sand casting? There are several reasons why you should consider custom aluminum die casting.

Ability to Deal with Complex Geometries

Die casting molds can easily create intricate designs and shapes. You can make thin walls, parts, small details, and integrated features, such as mounting bases, in a single process.

High Production Efficiency

The die casting process has speedy cycle times. Once the custom aluminum die casting mold is ready, you can produce thousands of customized aluminum die casting parts in just one day. Therefore, it is suitable for mass production businesses.

Cost-effective for Large Volumes

The initial costs may be higher. But in the long run, high speed and minimal post-processing will decrease the per-part cost. Thus, the method becomes a more economical choice for manufacturing large quantities.

Excellent Surface Finish

Customized aluminum die casting parts produced through die casting have a smooth and high-quality surface finish. Sometimes, you may not need additional post-processing for each part. Eventually, it will save on your overall costs.

High Accuracy and Tight Tolerances

The steel dies used in casting are extremely precise. The results from every mold remain constant, with a tolerance ranging from ±0.002″ to ±0.004″.

Efficienza del materiale

Since die casting is a near-net-shape process, the finished item is very close to its proper size. Thanks to its precision level, it reduces material waste, making it a reliable method.

Strength & Durability

Customized aluminum die casting parts are known for their high strength-to-weight ratio. The rapid cooling creates a firm and fine-grained surface, which enhances the overall strength and durability. And it’s a perfect choice for demanding applications.

Integration of Features

You can design the die, including optional features such as holes, ribs, or logos. These small features may replace the multiple smaller parts. Therefore, there will be no need for assembly, which simplifies the product and reduces costs.

Scalabilità

Custom aluminum die casting is highly scalable. You can use the same die to produce small or millions of parts for mass production. Moreover, it allows you to justify the mold before placing small batch orders.

Why Choose Aluminum Die Casting Parts?

You might also wonder why Aluminum alloy is used, rather than zinc alloy or other alloys. Well, aluminum alloy is ideal for various reasons. It is lightweight, widely available, and, of course, has high strength compared to its weight.  For customized aluminum die casting parts, the following are the reasons why you should use aluminum alloy.

Leggero

Aluminum is a low-density material, which makes it one of the lightest metals. It’s a crucial property for applications where lightweightness is a top priority, such as in the automotive and aerospace industries.

High Strength to Weight Ratio

As mentioned before, despite its low weight, it is superbly strong. When die-casting, it can produce parts that are both light and durable. These parts are also ideal for handling high stress in harsh conditions.

Excellent Corrosion Resistance

Die-casting aluminum alloy is highly corrosion-resistant. Naturally, the aluminum forms a layer when it comes in contact with air. Thus, it makes the die-cast part durable in various environmental conditions.

High thermal and Electrical Conductivity

Aluminum is an excellent conductor of both heat and electricity. Therefore, you can create items such as heat sinks for circuits or components for electrical housings. These parts are essential for electricity and heat to flow out.

Better Casting Fluidity

Certain aluminum alloys have high fluidity when molten. It allows them to fill intricate and complex die cavities. This property plays a crucial role in complex geometric shapes, which are notoriously difficult to create.

Efficienza dei costi

As you are aware, the initial die casting tooling cost can be high. But the low material cost and overall system cost will compensate. Not only compensate, but the process will also lead to very low costs per part in high-volume production.

Wide Alloy selection

There is a wide variety of alloys, especially for the die-casting method. Each alloy offers distinct properties. It’s because of the combination of manufacturing materials. So, select one that perfectly suits your application.

Alta riciclabilità

Aluminum parts are nearly infinitely recyclable without losing their material properties. Additionally, these parts are long-lasting, making them eco-friendly. Melt down the aluminum and use it as many times as you want.

Surface Finishing Flexibility

Die-cast metal parts have a smooth finish immediately after molding. But they also accept a variety of post-casting finishes. To make them look better, you can paint, powder coat, or anodize them.

Custom Aluminum Hot Casting Vs Cold Casting

Customized aluminum die casting parts are exclusively made in the cold chamber. The key difference lies in how the molten material is handled. In the hot chamber process, the melting pot is typically coupled with the casting machine. This design is only suitable for low-melting metals, such as zinc (Zn) and magnesium (Mg) alloys.

In the cold chamber process, the metal is typically melted in a separate furnace section. After that, the molten metal was transferred by a ladle into the injection mold. The separation of the melting unit can handle high melting points. It can handle aluminum without causing any damage.

Choosing Customized Aluminum Die Casting Parts Manufacturers

Although you have chosen the correct casting method and aluminum alloy, selecting the proper manufacturer remains crucial. To ensure your customized aluminum die casting parts are of high quality, you must provide a production facility that guarantees it. In this case, you must carefully assess the manufacturer. You can analyze the factors below to get a conclusion and find the best die casting factory for your project.

Competenza tecnica

A good manufacturer should possess in-depth knowledge of the casting process. They must know how to optimize DFM to reduce faults and boost efficiency. This expertise will ensure a high-quality final product.

Experience R&D

Look for a factory with an expert Research and Development team. Their expertise will help you solve problems related to designs or technical issues.

Design & Engineering Support

The best manufacturers can provide a wide range of support, from design to engineering. They can help you with everything from 3D modeling and prototyping. Therefore, consider this support to achieve an optimal outcome.

Mold-Making Capability

The quality of mold making has a direct impact on the quality of the final product. A company with in-house mold-making has better control over the process. They can ensure precision and adjustment for instant issues.

Quality Control & Certifications

A reputable factory must adhere to strict protocols throughout the process. Additionally, they should hold recognized certifications, such as ISO 9001. These certifications demonstrate their commitment to constant quality.

Post-Processing Ability

Many parts may require further processing after casting. It can be machining, surface finishing, or plating. Therefore, you should select an entity that can perform post-processing. It will give your product a shinier finish.

Ability to Assemble Casting Parts

For complex parts, you may need assembly services. It would be more advantageous to choose a company that offers an assembly process. Such an ability will save you money and time simultaneously.

Reliable Customer Support

Reliable customer support is also an important part. A trustworthy company will have a customer support team that provides updates. Before selecting a manufacturer, consider their customer support.

Introducing Aludie Cast as Your Trusted Partner

Aludie is one of the famous die casting companies in China, situated in Dongguan city. When you partner with us, you will not only get a manufacturer, but also a dedicated team. We deliver precision engineering with high manufacturing efficiency, bringing your ideas to life. Our certifications include ISO 9001, ISO 14001, and IATF 16949, ensuring you receive the best experience.

Final Words

Custom die casting is an effective process for manufacturing metal parts. You have gone through an elaborate discussion about the entire topic. How it works and how to choose a reliable manufacturer for your project. If you have further questions regarding the die casting, don’t hesitate to contattateci. Our friendly team is always ready to assist and push you forward.