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.

How does high pressure die-casting work?

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:

Our Process for Die Cast Mold Tooling Fabrication and High Pressure Die Casting

To ensure consistency and quality, our work includes:

Die Cast Mold Design for Manufacturing (DFM) and Design

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.

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Die Casting Mold Tooling Fabrication

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.

High Pressure Die Casting

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.

high pressure die casting machine
parts made with high pressure die casting

Part Inspections

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.

Advantages of High Pressure Die Casting

High pressure die casting offers several advantages for the production of parts, including:

  • Rapid Cycle Times: The process is highly automated, allowing for rapid cycle times and high production volumes.
  • Continuous Production: Suitable for mass production applications where large quantities of identical parts are needed.
  • Intricate Designs: Can produce parts with complex shapes, intricate details, and thin-walled sections that might be difficult or impossible to achieve with other casting methods.
  • Precision Features: Ensures dimensional accuracy and tight tolerances, making it ideal for precision components.
  • Smooth Surfaces: Provides a smooth and consistent surface finish, often eliminating the need for additional machining operations.
  • Enhanced Aesthetics: Ideal for parts where appearance is important, such as automotive components or consumer electronics.
  • Wide Range of Metals: Can be used with a variety of metals, including aluminum, zinc, magnesium, copper, and lead-tin alloys.
  • Tailored Properties: Material selection can be tailored to meet specific mechanical, electrical, or corrosion resistance requirements.
  • Tight Tolerances: Achieves excellent dimensional accuracy and consistency, reducing the need for rework or scrap.
  • Interchangeable Parts: Ensures that parts produced are highly interchangeable, simplifying assembly and maintenance.
  • High Production Volumes: Well-suited for large-scale production, leading to lower unit costs.
  • Reduced Machining: Often eliminates or minimizes the need for secondary machining operations, further reducing costs.

Talk To Us About Your Needs & Get A Quotation

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