SHD Precision Diecasting

Product Proofing & Mass Production

Die-Casting Product Proofing and Mass Production Specifications

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

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).

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).

 

Prototyping vs. Mass Production Comparison‌

 

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