Custom die casting molds

Core Product & Service: Custom Die Casting Molds

Our core business focuses on the customized design and manufacturing of high-precision die casting molds, which are core production equipment for realizing integral forming of metal components via high-pressure die casting technology. Our core function is to deliver tailor-made, high-performance die casting molds that match the properties of different casting materials and the structural characteristics of components—ensuring uniform melt filling, tight dimensional control, and excellent structural density of cast parts, which are critical for components demanding precision assembly, load-bearing capacity, and corrosion resistance. Backed by a professional team of 45+ engineers and technicians, we leverage advanced CAD/CAM/CAE software (UG, AutoCAD, SolidWorks) to conduct in-depth simulation of the die casting process for various materials. This includes simulating melt flow, heat transfer, and solidification to optimize mold cavity structure, gating system, exhaust layout, and cooling design, thereby preventing common defects such as porosity, shrinkage, and cold shuts. Our custom molds are tailored to diverse industry needs (automotive, industrial machinery, new energy, 3C, etc.) and compatible with multiple casting materials (e.g., aluminum alloy ADC12/A380/A356, zinc alloy Zamak 3/Zamak 5), featuring exceptional wear resistance, stable casting performance, and extended service life.

Production Process & Supporting Technologies

The production of our custom die casting molds adheres to a strict industrial-grade standardized workflow, with flexible adjustments based on material characteristics and component complexity: 1. Demand Analysis & Custom Design (Collaborate closely with clients to confirm component specifications, performance requirements, casting material selection, and production capacity; conduct 3D mold modeling and CAE die casting process simulation to verify melt filling uniformity, structural integrity, and defect risk, and optimize the design for custom needs); 2. Raw Material Preparation (Select high-quality die casting mold steel (H13, SKD61, P20) with superior wear resistance and thermal stability, matched to the casting material's melting point and casting pressure; implement precision cutting via CNC flame cutting equipment); 3. Precision Machining (Perform CNC milling, grinding, EDM, wire cutting, and high-speed machining to ensure the machining accuracy of mold cores, cavities, and gating components, with key dimensions controlled within ±0.005mm; adjust machining processes according to custom component's precision requirements); 4. Assembly & Custom Debugging (Skilled technicians conduct manual assembly, install customized temperature control and exhaust systems, and perform multiple rounds of debugging on die casting machines to optimize parameters such as injection speed, pressure, and mold temperature, tailored to the selected casting material); 5. Quality Inspection & Delivery (Use coordinate measuring machines (CMM), X-ray flaw detectors, and tensile testing equipment to inspect mold dimensions and internal quality of trial castings; conduct targeted performance tests based on client's industry standards and provide detailed test reports). In addition to custom die casting mold design and fabrication, we also offer supporting processes such as post-casting machining (milling, drilling, tapping), surface treatment (anodizing, electroplating, powder coating), and finished product assembly. We also provide plastic injection molding and precision machining services to meet clients' diversified manufacturing needs.

Common Problems & Solutions in Custom Die Casting Mold Design & Fabrication

• Problem 1: Material-specific casting defects (porosity in aluminum alloy, oxidation in zinc alloy) - Solution: Conduct material-specific CAE simulation to optimize the mold's exhaust and gating systems; adjust die casting parameters (temperature, pressure, holding time) according to the material's melting point and fluidity; select high-purity raw materials and conduct targeted degassing (aluminum alloy) or anti-oxidation (zinc alloy) treatments; install customized auxiliary equipment (protective gas devices for zinc alloy, degassing units for aluminum alloy).

• Problem 2: Dimensional deviation of complex custom components - Solution: Enhance mold machining precision, controlling key dimensions within ±0.005mm; optimize the cooling system layout to ensure uniform cooling of complex structures and reduce thermal deformation; design a segmented holding pressure system based on component thickness distribution to compensate for material shrinkage; conduct multiple rounds of trial casting and dimensional calibration for complex structures.

• Problem 3: Poor mold compatibility with mass production requirements - Solution: Conduct production capacity simulation during the design phase to optimize mold cavity number and gating efficiency; select wear-resistant mold steel and enhance surface treatment to extend mold service life for mass production; design quick-change mold structures to reduce downtime; match mold parameters with clients' existing die casting equipment.

Frequently Asked Questions (FAQ)

• Q1: What types of custom die casting molds can you design and fabricate? - A1: We can customize die casting molds for various materials (aluminum alloy, zinc alloy) and components across industries, including automotive engine brackets, industrial gearbox housings, new energy motor shells, 3C electronic connectors, and consumer goods hardware. We support customization based on client-specific drawings, performance requirements, and production capacity.

• Q2: What is the lead time for custom die casting molds? - A2: Lead time varies by mold complexity (component structure, material type, and cavity number): Sample molds take 10-20 working days, mass production molds take 25-50 working days, and urgent orders can be completed in 7-15 working days with an additional fee. We will provide a detailed customized production schedule upon order confirmation.

• Q3: Do you provide quality assurance for custom die casting molds? - A3: Yes, we offer a 12-month quality guarantee for all custom die casting molds. During the guarantee period, if quality issues arise due to mold design or manufacturing (e.g., dimensional deviation, abnormal wear), we will provide free repair or replacement services. We also offer lifelong technical support for mold maintenance and die casting parameter optimization.

• Q4: Can you provide one-stop services including die casting production of finished parts? - A4: Yes, we are equipped with 25+ high-pressure die casting machines (80-1250 tons) compatible with multiple materials, as well as a professional post-processing workshop. We can provide integrated one-stop services from custom mold design, fabrication to finished product die casting, machining, surface treatment, and assembly, effectively reducing your communication costs and shortening the production cycle.

• Q5: What certifications do your custom molds and finished products hold? - A5: Our factory is certified by ISO9001:2015 and IATF16949 (automotive industry quality management system). The casting materials we use comply with ASTM, EN, and RoHS standards. We can provide relevant certification documents, material safety data sheets (SDS), and performance test reports according to client's industry requirements.

Product Classification & Technical Specifications

1. Product Classification by Industry, Material & Part Type

2. Technical Specification Parameters

Our Core Competitiveness

• 10+ Years of Custom Die Casting Expertise: Founded in 2012, we have focused on custom die casting mold design and fabrication, serving over 200 clients from more than 40 countries, including Europe, North America, and Southeast Asia. Our profound experience enables us to accurately grasp the unique technical requirements of different industries and provide targeted custom solutions.

• Professional Custom Technical Team: A team of 45+ engineers and technicians with an average of 8+ years of experience, proficient in custom die casting mold design, multi-material CAE simulation, and process optimization. They excel in solving complex technical issues such as high-precision custom molding, multi-material compatibility, and complex structure defect control.

• Strong Custom Production Capacity: Our 8,000-square-meter factory is equipped with 50+ sets of advanced production and testing equipment, including CNC milling machines, EDM machines, wire cutting machines, CMM, multi-tonnage high-pressure die casting machines, and X-ray flaw detectors. We have an annual production capacity of 100+ sets of custom die casting molds.

• Strict Quality Management System: Certified by ISO9001:2015 and IATF16949, we implement full-process quality control from raw material inspection to finished product delivery. Our professional quality inspection team and complete testing equipment ensure the stability and reliability of custom molds and components, complying with international standards.

• Improved Supply Chain for Customization: We cooperate with reliable domestic suppliers to ensure stable supply and consistent quality of various casting materials and mold steel. By integrating upstream and downstream resources, we achieve cost optimization and timely delivery for custom orders, effectively supporting clients' mass production plans.

• Global Custom Service Capabilities: Partnering with renowned international logistics companies (Maersk, COSCO), we leverage Qingdao Port's geographical advantage to provide efficient and safe global shipping. We offer 24-hour online technical support and a 12-month quality guarantee, promptly addressing after-sales issues for global clients' custom projects.

Customer Case: Multi-Material Custom Die Casting Mold Project for European Automotive Tier 1 Supplier

Our client is a leading automotive Tier 1 supplier in France, specializing in automotive powertrain components. They needed custom die casting molds for two key components: aluminum alloy engine brackets (A356) and zinc alloy sensor housings (Zamak 5), with challenges including complex engine bracket structures (multiple thick-walled areas leading to shrinkage) and high precision requirements for sensor housings (dimensional tolerance ±0.015mm). Their previous supplier failed to meet both material's casting requirements simultaneously, resulting in delayed production. In 2019, they partnered with us for a one-stop custom die casting mold solution.

Our technical team first conducted a detailed analysis of the two components' drawings and automotive industry standards (IATF16949). For the aluminum alloy engine bracket, we used UG software to build a 3D mold model and performed CAE simulation, optimizing the cooling system with segmented cooling channels for thick-walled areas and adding 32 exhaust ports to eliminate shrinkage. For the zinc alloy sensor housing, we adopted a pinpoint gating design and micro-exhaust structure to ensure uniform filling and surface finish, selecting H13 mold steel with precision polishing (Ra ≤ 0.05μm). We also adjusted die casting parameters separately for A356 (injection temperature 700℃, mold temperature 220℃) and Zamak 5 (injection temperature 435℃, mold temperature 180℃) during debugging, conducting multiple rounds of tensile tests and dimensional inspections.

The final delivered custom molds achieved outstanding results: The aluminum alloy engine brackets had no shrinkage defects, and tensile strength reached 230MPa; the zinc alloy sensor housings' dimensional accuracy was controlled within ±0.015mm, fully meeting automotive assembly requirements. Production efficiency for both components increased by over 120% compared to the client's previous supplier, and the mold service life was guaranteed to exceed 1.5 million shots. The client highly recognized our custom technical capabilities and one-stop service, signing a long-term cooperation agreement covering multiple automotive component custom molds.

Why Choose Qingdao Xinlongji for Custom Die Casting Molds?

1. Professional Customization Capabilities: We focus on custom die casting mold design and fabrication, with in-depth insights into multi-material properties and cross-industry standards, ensuring custom solutions that precisely match your component and production needs.

2. One-Stop Integrated Service: From custom mold design, fabrication to finished product die casting, machining, and assembly, we streamline the supply chain, reducing your communication and management costs. We also offer supporting processes for other materials to meet diversified demands.

3. Proven Technical Strength: Our advanced multi-material CAE simulation technology and professional engineering team effectively solve complex custom challenges (e.g., complex structure molding, multi-material compatibility), ensuring product quality and production efficiency.

4. Reliable Quality Assurance: International quality certifications and full-process quality control ensure our custom products meet global standards, minimizing your production risks and facilitating your entry into international markets.

5. Efficient Global Support: With rich international trade experience and mature global logistics channels, we guarantee timely delivery of custom orders. Our 24-hour technical support team addresses after-sales concerns, providing peace of mind throughout your production process.

Qingdao Xinlongji Metal Manufacturing Co., Ltd. is committed to becoming a trusted partner in the global custom die casting mold industry. We look forward to collaborating with you to create tailored, high-quality manufacturing solutions for your business! For more information on our custom products and services, please feel free to contact us.