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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
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).


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