Agilian makes aluminum and zinc parts. More specifically, we design and fabricate your die casting molds in-house, and then we manage production in a casting factory nearby. We then do machining as needed to finish your metal parts. That’s how we keep quality under control.
The molds are typically made from DIN 2344 die steel which is required to withstand the high temperatures, pressure, and shocks, for many thousands of uses.
Similarly to plastic injection molds, die casting molds allow complex parts to be made in large quantities, efficiently, and with consistent results. Many industries that use metal parts take advantage of die casting in one way or another.
Molten metal is forced under pressure into the mold cavity, which takes on the desired shape of the part and is ejected once cooled and hardened. Different metals can be used to suit your application and we work mainly with Aluminum and Zinc alloys.
Learn more about the die casting process here:
We start with a thorough DFM analysis to ensure your mold design is optimized for manufacturability. Our mold designers use CAD software to create your die casting mold’s design based on your product’s requirements. The designers can assist with material selection if needed. We do draft analysis, mold flow simulation, and other important verifications to predict and address potential issues with the tooling before fabrication begins.
When the design is ready it is passed over to our tooling fabrication team to actually produce the molds. By default they tend to use DIN 2344 die steel which offers a great mix of stress and abrasion resistance.
Tooling is made using our precision machining equipment, including CNC machining centers and EDM (Electrical Discharge Machining). Complex features such as ejectors, thread, undercuts and more, are common.
After the mold tooling has been fabricated, we manage the production of your parts at a specialized factory near Agilian. Customers are free to visit during production of their parts.
We typically handle the secondary processing, for example drilling or milling. And, if the parts need surface treatment (e.g. powder coating, plating…), we can also manage that activity.
The overall purpose is that, by making the molds and managing the supply chain tightly, we keep control of both quality and ‘who does what’. Our customers expect visibility and we have to deliver on that aspect.
We are flexible enough to offer small batch manufacturing or larger quantities.
We review the parts’ design. We make the molds. There is a part review & sign-off process before mass production starts. However, those are not enough.
Inspecting the parts for dimensional accuracy and for aesthetic considerations is also part of a quality assurance system. Our quality department applies a mix of first-article inspection, in-process inspections, and final inspection before a batch is shipped.
