Flagship's Comprehensive Process for Die Casting Mold Production

1. Request For Quote (RFQ)

Provide quotations within 24 hours after receiving a detailed RFQ, along with a preliminary die layout.

Quote information:

· a) 2D/3D part data. (essential)

· b) Quantity of cavity/cast requirement.

· c) Steel requirement.

· d) Die casting machine.

2. Design For Manufacturing (DFM)

Deliver DFM within 2 working days.

For each die-casting mold, we perform DFM, analyzing the parting line, gate and overflow, ejection, and potential concerns in the part analysis report.

3. Flow Simulation amp; FEM

Three experienced simulation technicians.

We conduct Simulation & FEM for each die-casting mold, performing filling, temperature, solidification, and cycle simulations upon request. These simulations enable the creation of casting-optimized geometries during the development phase of a part. We assess the strength of highly stressed die components, such as holder blocks and the locking surfaces of heavily loaded slides, during the design process using Flow3D simulation and calculation software.

4. Mold Design

15 experienced engineers for design and 3D modeling. Mold design provided within 3-4 working days.

Our 3D die design is based on customer specifications, from the initial concept to the finished die. Interfaces: X-T, IGES, and STEP. CAD systems: Siemens NX.

5. Engineering Work

Fast response time and flexible service, with direct communication in English.

Our ERP system provides an overview of the entire process chain, ensuring on-time lead times. With many years of experience exporting die-casting molds, our strong engineering team offers effective suggestions for the development process, optimizing the castability of the desired castings. The knowledge and understanding of each phase of the development process influence every step in creating a die-casting die. Weekly schedule updates (every Monday).

6. Quality Control

3 qualified measuring technicians working in 2 shifts.

To ensure mold quality and on-time lead times, we perform inspections at each step in-house, from material to machining. Using HEXAGON for precise measurement (CMM), HEXAGON for precise measurement (Profile Projector), hardness testing machines, microscopes, and ultrasonic inspection.

7. Sampling

Provide a trial report and video clip within 24 hours after completing the trial.

To ensure the dimensional accuracy of the molds before delivery to our customers, we independently perform die samples. This includes sampling aluminum, magnesium, and zinc castings. We use infrared thermography to confirm if the mold temperature is sufficient to start the trial, avoiding the risk of mold cracking from sampling at unsuitable temperatures.

8. Inspection Report

3 qualified measuring technicians working in 2 shifts.

Upon customer request, we produce initial sample test reports in-house with full documentation, employing HEXAGON for precise measurement (CMM) and HEXAGON for precise measurement (Profile Projector).

9. Maintenance

Preventive and planned tool maintenance.

We offer customer service and assistance in finding solutions to specific problems, introducing changes or optimizations to an already completed die. Our goal is to help our customers maintain problem-free mass production, ensuring production stability and reducing costs, and maximizing tool life utilization.

Feel free to send an inquiry to [email protected] to get a free quotation and share more information with die casting industry.