Slide ✓ High experienced in the UK market
✓ Hypercompetitive pricing
✓ Fast tooling and tool-modification
✓ Consistent quality
✓ No Minimum Order Quantity (MOQ)
✓ ISO 9001:2015 certified
✓ CMM / SGS reports available
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PRESSURE DIE CASTING

Inodus are experts in the field of die casting. Our team has been working with reputable foundries in the UK and China for more than a decade.

 

Our core foundry partner produces their own tools and is located in Ningbo, one of the leading locations in the world for die casting. With our technical know-how and capability, we are able to produce challenging parts (thick walls, tall fins, minimal draft angles, complex cores etc.) which EU and UK competitors may not be able to make. In addition, our core partner has a long-proven track of record supplying UK manufacturers, making products used in many UK key infrastructure projects. Major clients include leading global corporations in different sectors, such as telecom, automobile, electric vehicle, lighting, etc.

 

In essence, what we offer is the combination of best tooling cost and part cost, easy DFM, superior FOTS (First out of tool sample), quick technical communication and consistent quality.

 

Inodus can also offer a stock holding up to a year in the foundry’s storage to facilitate logistic turnaround. If you require high volume production each month, we can also arrange transfer of the tool to a UK foundry of your choice.

Pressure die casting capability overview

Pressure die casting
Maximum part size
Depending on geometry, max slider size 1600 x 1600 mm
Special dimension upon request
Casting machine capacity
Up to 4500T
>4500T upon request
Tool lead time
10 – 20 days ( rapid tool, for low volume production )
30 – 45 days ( typical high volume production tool )
60 – 90 days ( very large tool )
Typical tool life
1,000 cycles ( soft tool, for special prototyping )
20,000 cycles ( rapid tool )
50,000 - 100,000 cycles ( production tool, depending on tool material )
FOTS (First off-tool) lead time 5 - 10 days
Standard linear tolerance
L ≤ 25mm, ± 0.05 mm
For each additional 25mm, ± 0.025mm

Slide 5G cavity filter Slide Telecommunication equipment Slide Fuel tank Slide Gear box Slide Braking system component Slide Engine cover Slide Highbay LED luminaire Slide Electronic enclosure Slide Diesel engine block Slide Clutch cover

When to use pressure die casting

  • Aluminium, magnesium and zinc parts with complex geometry
  • Large volume mass production with low unit cost
  • Widely used in all industrial sectors ranging from small simple parts to large complex components.

CAD re-model service for die casting

If you are not familiar with creating CAD models to suit die casting manufacturing, we are able to offer a re-modelling service (creating draft angles and vary wall thickness, etc.) to suit the casting process.  This service is free of charge once the tooling has been ordered. Depending on complexity a slightly longer lead time will be required.

Available materials for pressure die casting

Inodus offers the most comprehensive selection of materials.  If your required material is not in the list, we will try our best to source it for you. If you are not sure which material is best for your application, our design engineers are here to help.

Types Application considerations
Aluminium alloy Light weight, good mechanical, thermal and electrical conductivity
LM24 (A380) Die casting alloy, general purpose
LM2 (A383/ADC12) Slightly lower density to LM24, poor weldability / brazeability
LM6 (A413) Marine grade, with higher corrosion resistance. Common choice for UK market where the end product will be exposed to outdoor environment.
AlSi10MnMg (EN AC-43500) High performance, complex, thin-walled, pressure-tight and vibration resistant castings with high strength after curing, with very good corrosion resistance. Advanced use in automobile industry for structural components.
Magnesium alloy Light weight (33% lighter than Aluminium), high strength-to-weight ratio, great damping capacity. More expensive than aluminium, and could bend easier under stress
AZ91D Most widely used magnesium die cast alloy and has an excellent combination of mechanical properties and corrosion resistance
Zinc alloy More precise than aluminium, and allowing smaller draft angle, thinner wall section, smaller and longer cored holes. Lower casting cost. Not good for corrosive environment, not suitable for using in high or low temperature (below 0°C) environment.
Zamak 2 Greatest strength of all Zamak,but more brittle and shrinks overtime, less elastic
Zamak 3 Long term dimensional stability
Zamak 5 Increased strength, hardness and corrosive resistance, but reduced ductility, less dimensional accuracy
Zamak 7 Increased ductility

Post-processing service for die casting

Service
Heat treatment T4, T5, T6 etc.
CNC machining Additional machining Drilling and tapping
Sand / bead blasting  
Anodizing Type II (glossy) Type II (matte) Type III (hardcoat) Various colour
Plating Nickel, zinc, tin, brass, copper, silver, gold, Teflon impregnated, copper
Powder coating To any RAL colour
Part marking Laser etching, laser engraving
Electropolishing  
Brushing  
Chromate conversion coating  
Other finishes Mixture of above, UV protection coating, Teflon coating, Sand blasting, Brushing Polishing, Vapor polishing (plastic only)

Slide Mould storage area Slide EDM stations Slide EDM (electrical discharge machining) Slide Die spotting press Slide Blasting machine Slide Small CNC stations Slide Large CNC stations Slide Castings storage Slide Coordinate-measuring machine (CMM) Slide X-ray and chemical analysis

Facility Audit

We understand that sometimes your company will need to perform an audit or a third-party QC firm to approve the project. We are highly experienced in both and can make arrangements if you decide to visit the production site.

Frequently asked questions

What’s the difference between Gravity die casting and Pressure die casting

The gravity die casting rely on gravity to fill the mould while pressure die casting allows alloy to be injected quickly. Pressure die casting is far more automated and thus have very high productivity and reduced human error.

Tooling cost for gravity die casting is much lower than pressure die casting due to the use of cast iron instead of hardened steel for the mould, plus that the pressure die casting require sophisticated internal cooling channel design.

 

The advantage of gravity die casting is that the part in as-cast state is stronger than pressure die casting (without subsequent heat treatment), thanks to the slower speed the molten metal enters the mould, which reduced air trapped inside. The choice of which process to be used thus depend on the estimated total quantity and economic factors. We can help you decide which casting solution is best for your project.

What if a tool modification is required

Most minor tool modifications (such as adding a boss or a rib) will be free of charge. Because our foundries produce their own tool, the turnaround time is quick. Remember that adding material to the parts ( = removing material from the tool) is much easier than removing material to the parts ( = adding material from the tool, which involves welding and could shorten the tool life)

Tool ownership and transfer

You have the complete ownership of the mould. The mould by default is stored permanently without any expiry date. If there’s any need to transfer the tool to a UK foundry it’s easy to do so. It is also common for the mould to be made first than shipped to a UK foundry for subsequent casting (see tool making service)

What happens after the tool exceed its lifespan

Tool wear and damage can occur, resulting in sub-standard parts (more burrs, breaking edges, uneven surfaces etc.). Although in most cases mould can be repaired to extend its lifespan, other factors need to be considered whether making a new tool is more economical.

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