The Status of Die-Casting Molds in Industry

The Status of Die-casting Molds in Industry

Molds are indispensable basic tools in manufacturing and an important symbol to measure the level of a country’s manufacturing industry. Large die-casting molds that are complex, precise, and long-lived reflect the highest technical level. For a long time, developed countries such as Europe, America, and Japan have implemented strict technological and standard blockades, and most of my country’s high-end die-casting molds rely on imported technologies.

The Status of Molds in Industry

“The mold industry is the cornerstone of American industry” (USA)
“Molds are the driving force for social prosperity” (Japan)
“Molds are the emperors in metal processing” (Germany)
“Molds are gold” (Romania)
“The mold industry is an ever-lasting industry” (Europe)
“The mold industry is the pearl in the palm of manufacturing” (Taiwan)
“Molds are efficiency amplifiers” (Singapore)

Molds are the mother of industry. 80% of the problems in the production process come from molds, so molds are the most important tools in our production.

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Application Range of Die-Casting Molds

Die-casting molds involve more than 30 industrial fields such as aviation, automobile, motorcycle, electronic information and communication, municipal administration and lighting, energy, machinery, construction hardware, household appliances, and medical equipment. Most of people’s daily travel and communication tools, lighting, and home appliances are related to die-casting products produced by die-casting molds. The application range of die-casting products is second only to that of stamping and plastic products. Moreover, with the development of lightweight new energy vehicles in the future, die-cast aluminum and magnesium alloys will definitely enter a period of rapid growth, and their proportion in automobiles and other fields will increase year by year.

Although there are many types of molds, the commonly used molds in production are stamping dies, plastic molds, and die-casting molds. According to the data from the Mold Industry Association, stamping dies account for about 40% to 50% of the total mold quantity, injection molds account for about 20% to 30%, and other molds account for about 20% to 40%.

The automotive industry is the largest user of the mold industry:

A small car probably uses 8,000-15,000 molds.
A mid-range sedan probably uses 15,000-30,000 molds.

What is a Die-Casting Mold?

Die-casting is the abbreviation of pressure casting!

A die-casting mold is a mold used in the process where high-temperature molten or semi-molten metal is filled into the mold cavity at a high speed under high pressure and solidified quickly under pressure to obtain castings. The mold used in this process is called a die-casting mold.

Hot chamber die-casting molds
Cold chamber die-casting molds

Essential Factors and Production Process of Die-Casting Mold Production

Three essential factors for die-casting production: alloy raw materials, die-casting machines, die-casting molds.

Die-casting production process: melting materials → clamping mold → pressure die-casting → cooling and solidification → opening mold → taking out castings.

Applications of Die-Castings in the Automotive Field

Wiper system	Engine system	Filter system
Air conditioning system	Shock absorption system	Precision compressor parts
Power steering control system	Brake control system (ABS)	Rearview mirror system
Transmission	Car seats	Car wheels
Shock towers	Chain covers	Steering knuckles
Car suspension beams	Oil pumps	,etc.

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Die-Castings in the Communication Field

Dual-tower amplifiers	Mobile phone panels	Chassis components	Filters
Upper cover of portable signal devices	Lower cover of portable signal devices	Mobile phone middle frames	Radiators, etc.

Die-Castings in the Computer Field

All-in-one machine back covers	Laptop brackets	Radiators	Key panels
3-piece set of desktop computer hard disk enclosures	Laptop bottom covers	Screen frames	Heat dissipation systems
LCD monitor bottom covers	Laptop PCB brackets	Bottom covers	,. etc

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High Pressure Die-Castings in the Lighting Field

Street lamp enclosures	LED lamp covers	Shields	Radiators
Square lamp enclosures	advertising lamp brackets	Fixed plates	.,etc

Applications of Die-Castings in the Electrical Appliance Field and the Motor Field

Razor enclosures	Handle enclosures	Motor casings	Motor covers
Rotating bases	LED box brackets	Motor end covers	Upper motor covers
Office chair feet	LED frames	Micro motor casings	Lower motor covers
Submarine driver enclosures	Bar chairs	Motor back covers	Motor brackets
Cutting machine enclosures	Meat grinders	Rear end covers	., etc

aCatTech R&D, Design, Manufacturing, and Batch Production Capabilities

During the vehicle R&D stage of the main engine factory:

We start from the initial concept of the customer’s product and cooperate closely with the customer to jointly evaluate the feasibility of product design and the batch stability of subsequent production.

Rapid prototype test molds: CAD and CAE auxiliary design and analysis to ensure the feasibility of the scheme.
We can assist main engine factories in the preliminary design and development and process evaluation of alloy parts and structural parts for the power section, and can also quickly develop die-casting molds for test prototypes, providing efficient services for the preliminary testing of the main engine factory’s entire vehicle.
Complete the production of complex rapid test molds within 5-6 weeks.
Small-batch production of rapid test prototypes can be completed in 3-5 days, providing main engine factories with the fastest parts that are closest to subsequent production.

For mass production, we have 22 sets die-casting machines. For more information, please contact us here

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Benefits That aCatTech Technological Innovation Can Bring to Society

Motors are the source of power in the industrial field. They realize the mutual conversion of electrical energy and kinetic energy through the action of electricity and magnetism. Motors occupy a very important position in the global industrial automation market and are widely used in metallurgy, petrochemicals, electric power, coal, mining, building materials, papermaking, municipal administration, water conservancy, shipbuilding, port loading and unloading, and other fields.

The traditional method of making motor casings is to first die-cast an aluminum alloy blank with machining allowance, and then process the red surface through a lathe to meet the assembly requirements.

Through technological innovation, we optimize mold design and manufacturing, and achieve one-time die-casting forming, which can meet the assembly requirements without inner hole processing. The processing time for a single motor is reduced by at least 1 minute. If the annual demand for a single product is 100,000 units, it will reduce 100,000 minutes. Calculated at 10 cents per minute, a single product can save at least 100,000 × 0.1 = $ 80,000 per year. If calculated based on 10,000 sets of motor molds per year, it will save more than 8 billion in processing costs.

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