Custom Aluminum Castings – Full-Process Solution (Steel Mold Casting/Die Casting + CNC Machining)

1. Solution Overview

This custom aluminum casting service centers on “full-category coverage, multi-process adaptation, and high-precision delivery.” It addresses pain points of traditional aluminum castings (long customization cycles, single process, insufficient precision, difficult material adaptation) by providing a full-chain service from “design optimization – mold development – casting production – CNC precision machining – surface treatment.”

It supports customization of various aluminum castings (housings, brackets, special-shaped structural parts) and two core processes: steel mold gravity casting and high-pressure die casting. Equipped with CNC precision machining (accuracy up to ±0.01mm) and multi-material customization (ADC12, A356, 6061, etc.), it serves industries such as automotive, new energy, industrial equipment, and electronic communications. With flexible delivery (from 1 piece to mass production), it helps customers shorten product development cycles by 30% and reduce manufacturing costs by 20%.

2. Core Capability System

2.1 Full-Category Custom Aluminum Casting Coverage

• Multi-Type Structure Adaptation:

Customizable from micro precision parts (e.g., electronic connector housings, minimum size 5×3×2mm) to large structural parts (e.g., new energy vehicle battery trays, maximum size 2000×1500×200mm). Covers full categories including housings (motor housings, controller housings), brackets (equipment support arms, mounting brackets), special-shaped parts (complex flow channel parts, integrated structural parts), and functional parts (heat sinks, transmission gearboxes) to meet structural and functional needs of different scenarios.

• Complex Structure Implementation:

Supports customization of aluminum castings with wall thickness 0.8-50mm, enabling designs such as complex inner cavities, hollow structures, multi-step features, and pre-cast threaded holes. CAE simulation optimizes casting processes to avoid defects like shrinkage holes, air holes, and cracks, with a pass rate of ≥95% for one-time molding of complex structural parts.

• Balance of Lightweight and Strength:

Leveraging aluminum’s properties (density 2.7g/cm³, 1/3 of steel), structural topology optimization (e.g., rib design, uniform wall thickness) reduces casting weight by 20%-40% while ensuring tensile strength ≥200MPa and yield strength ≥120MPa (adjustable by material), meeting dual requirements of lightweight and structural strength.

2.2 Dual-Process Adaptation: Steel Mold Casting + Die Casting

• Steel Mold Gravity Casting (Sand Mold/Metal Mold):

◦ Application Scenarios: Large structural parts (e.g., industrial equipment bases, wind power accessories), thick-walled parts (wall thickness ≥5mm), low-volume customization (100-500 pieces). Molds made of 45# steel or H13 hot work die steel, with service life ≥50,000 cycles.

◦ Process Advantages: High casting density (≥2.6g/cm³), stable mechanical properties. Covers aluminum alloy grades A356, A380, 6061, suitable for strength-critical scenarios (e.g., automotive chassis brackets).

• High-Pressure Die Casting:

◦ Application Scenarios: Small-to-medium precision parts (wall thickness 0.8-5mm), mass production (≥1000 pieces) such as new energy vehicle motor end caps and electronic device housings. Molds made of H13 hot work die steel with surface nitriding, service life ≥100,000 cycles.

◦ Process Advantages: High production efficiency (up to 15 seconds/piece), high dimensional accuracy (CT5-CT7 grade), good surface finish (Ra≤1.6μm), reducing subsequent processing and costs.

• Flexible Process Switching:

Provides process selection suggestions based on customer needs (volume, size, precision, cost). For example, steel mold casting for small-batch complex parts, die casting for large-batch precision parts, achieving precise “demand-process” matching.

2.3 CNC Precision Machining & Surface Treatment

• High-Precision CNC Machining:

Equipped with vertical/horizontal CNC machining centers (maximum stroke 3000×1500×1000mm) and 5-axis machining centers, supporting subsequent precision machining of aluminum castings. Machining accuracy up to ±0.01mm, capable of planar milling, hole system machining, thread machining, and complex surface machining, meeting high-precision requirements for key parts (e.g., H7 tolerance for bearing seats).

• Full-Series Surface Treatment:

Offers anodizing (natural, black, colored; film thickness 5-20μm; salt spray resistance ≥48 hours), electrophoretic coating (corrosion resistance ≥class 10), spraying (powder/liquid spraying; weather resistance ≥5000 hours), passivation (improves surface corrosion resistance), and sandblasting (matte/high-gloss surface effects). Adapts to usage needs of different environments (e.g., spraying for outdoor equipment, anodizing for electronic parts).

• Quality Inspection Assurance:

Uses coordinate measuring machines (accuracy ±0.005mm), metallographic microscopes, and tensile testing machines to fully inspect dimensional accuracy, metallographic structure, and mechanical properties of aluminum castings, ensuring delivery pass rate ≥99.5%.

3. Customization Service System

3.1 Full-Dimension Customization Scope

 

Customization Dimension	Customization Content & Parameters
Type Customization	Housings (5×3×2mm to 2000×1500×200mm), brackets, special-shaped parts, functional parts; supports complex structure design
Process Customization	Steel mold gravity casting (sand/metal mold), high-pressure die casting; optional CNC machining (accuracy ±0.01mm)
Material Customization	Common materials: ADC12 (die casting preferred, tensile strength ≥220MPa), A356 (casting preferred, tensile strength ≥240MPa), 6061 (high strength, tensile strength ≥310MPa); Special materials: Al-Si-Mg series, Al-Cu series (composition adjustable on demand)
Precision Customization	Casting accuracy: CT5-CT10 grade (CT5-CT7 for die casting, CT8-CT10 for gravity casting); Machining accuracy: ±0.01mm-±0.1mm (selectable by demand)
Surface Customization	Anodizing, electrophoresis, spraying, passivation, sandblasting; supports custom colors (Pantone matching) and film thickness (5-20μm)

3.2 Customization Process

1. Needs Communication: Customers provide drawings (2D/3D), application scenarios, performance requirements (strength, corrosion resistance), volume, and delivery cycle; we offer process and material selection suggestions.
2. Design Optimization: CAE casting simulation to optimize structures (e.g., avoiding uneven wall thickness, adding vent holes) and reduce casting defect risks.
3. Mold Development: Steel molds (45# steel/H13 steel) made based on process type; mold trial to confirm sample size and appearance.
4. Sample Confirmation: Produce first samples, conduct dimensional inspection and performance testing; start mass production after customer confirmation.
5. Mass Production: Perform casting, CNC machining, and surface treatment per confirmed process; conduct sampling inspection during production.
6. Delivery & After-Sales: Deliver per agreed cycle (support express/logistics), provide 1-year warranty, and respond to after-sales issues within 24 hours.

4. Typical Industry Application Cases

1. New Energy Vehicle Sector: Custom high-pressure die-cast motor end caps for automakers (material ADC12, size φ200×80mm, wall thickness 3mm) — Adopts high-pressure die casting + CNC precision machining, casting accuracy CT6 grade, H7 tolerance for bearing seats after machining, anodized surface. Volume: 100,000 pieces/month, delivery cycle 7 days, cost reduced by 18% compared to traditional processes.
2. Industrial Equipment Sector: Custom steel mold cast equipment bases for equipment manufacturers (material A356, size 1200×800×150mm, wall thickness 10mm) — Adopts sand mold gravity casting, CNC milled surface (flatness ≤0.05mm/m), sprayed surface. Volume: 500 pieces, tensile strength ≥240MPa, meets 500kg equipment load requirement, one-time molding pass rate 98%.
3. Electronic Communications Sector: Custom precision die-cast housings for communication companies (material ADC12, size 50×30×15mm, wall thickness 1.2mm) — Adopts high-pressure die casting + 5-axis CNC machining, realizes complex inner cavities and threaded holes, black anodized surface, accuracy ±0.02mm. Volume: 10,000 pieces, meets lightweight and electromagnetic shielding needs of communication equipment.

5. Core Competitive Advantages

• High Customization Flexibility: Customizable from micro parts to large parts, from single samples to mass production, supports complex structures and special materials. Solves the “customization limitation” issue of traditional aluminum castings.
• Strong Process Integration Capability: Independently masters full-process technologies (steel mold casting, high-pressure die casting, CNC machining, surface treatment) without outsourcing. Reduces intermediate links, ensuring quality control and stable delivery cycles (3-15 days for mass orders).
• Excellent Quality Stability: Uses H13 hot work die steel for molds, CAE simulation for process optimization, full-process inspection (coordinate measurement, tensile testing). Casting pass rate ≥99.5%, mechanical property compliance rate 100%, far exceeding industry average.
• Significant Cost Efficiency: High-pressure die casting improves production efficiency by 3x, CNC machining reduces subsequent assembly processes, long mold service life (≥100,000 cycles for die casting molds). Long-term mass production reduces unit cost by 20%-30%.
• Rapid Service Response: Professional engineer team (over 10 years of aluminum casting experience) provides 1-on-1 needs docking. Mold development cycle 20-30 days (industry average 35-45 days), after-sales solutions provided within 24 hours.

6. Cooperation Guarantee

• Technical Guarantee: Free structure optimization and process selection services to help customers reduce design risks.
• Quality Guarantee: Provides material reports, dimensional inspection reports, and performance test reports; supports third-party inspection by customers.
• Delivery Guarantee: Mold development cycle 20-30 days, mass order delivery 35-45 days; supports emergency orders (samples available within 48 hours).
• After-Sales Guarantee: For quality issues (non-human damage), free replacement/refund and freight coverage are provided; lifelong technical support is offered.