Product Proofing & Mass Production

Die-Casting Product Proofing and Mass Production Specifications

(Applicable to automotive components/consumer electronics casings/aerospace parts)‌

I. Prototyping Stage‌

‌Rapid Design Validation‌

· ‌Methods‌:

· 3D-printed trial molds (metal/resin) for structural verification (≤48 hours).

· Digital twin simulations to predict defects (shrinkage/flow marks).

· ‌Tools‌:

· Lightweight molds (low-carbon steel/aluminum composites, 40% cost reduction).

‌Small-Batch Trial Production‌

· ‌Key Parameters‌:

· Injection speed: AI dynamic adjustment (±5% tolerance).

· Mold temperature control: Segmented cooling (ΔT ≤3°C).

· ‌Inspection Requirements‌:

· Full CMM scanning for first-piece inspection (±0.05mm tolerance).

· X-ray inspection for internal porosity (defect rate ≤0.1%).

‌Documentation Delivery‌:

· Trial production report (CAE simulations + blockchain records).

· Mass production feasibility assessment (cost/cycle/carbon footprint).

‌II. Mass Production Stage‌

‌Process Optimization‌

· ‌Smart Parameter Configuration‌:

· IoT sensors on molds feed real-time data (temperature/pressure) to MES systems.

· Adaptive injection curves (AI algorithm updates every 24 hours).

· ‌Energy Control‌:

· Energy consumption ≤1.2kWh per unit (≥50% green energy usage).

‌Large-Scale Production‌

· ‌Production Line Setup‌:

· High-speed die casting machines (clamping force ≥3,500 tons, cycle time ≤45s/piece).

· Robotic automated part removal + deburring (±0.1mm precision).

· ‌Quality Monitoring‌:

· Spectral analysis every 100 pieces (alloy composition deviation ≤0.5%).

· AI visual inspection for surface defects (miss rate ≤0.01%).

‌Sustainability Management‌:

· Scrap recycling rate ≥99% (direct smelting reuse system).

· Blockchain-based carbon footprint tracking (raw material to delivery).

‌III. Prototyping vs. Mass Production Comparison‌

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‌IV. Compliance & Risks‌

⚠️ ‌Mandatory Requirements‌:

· Designs without digital twin validation are prohibited for trials (ISO 22163:2025 §4.5).

· Mass production molds must embed IoT sensors (Smart Factory Standard 2025).