How to Obtain High-Precision Die-Cast Parts for Medical Devices and Aerospace in Large Quantities

1. Requirements Analysis and Design Phase

Custom Aerospace Parts Manufacturing

• Requirements Collection: Determine the performance requirements of aerospace die casting parts, such as product durability, strength, weight, material selection (such as aluminum alloy, magnesium alloy, etc.)
• Design Verification: Create 3D models through CAD (computer-aided design) to ensure that part designs meet the precision requirements of medical devices and aerospace
• Design Optimization: Use CAE (Computer Aided Engineering) to optimize die casting part design and flow channel system to ensure fluidity and accuracy during die casting

Material Selection: Select high-strength and lightweight die-casting materials according to your needs to ensure precision requirements and long-term performance

What Materials Are Best for Custom Medical Parts and Accessories?

In orthopedic surgery, titanium and its alloys are often used for limb and skull reconstruction, artificial joints, implants, etc. Cobalt alloys are more suitable for implants that bear long-term body loads, such as hip and knee joints. Stainless steel is used to produce fracture prevention equipment and artificial heart valves.

Medical precious metals (such as gold, silver, and platinum) are often used in implantable electrodes and electronic devices due to their excellent conductivity. Medical-grade plastics are widely used in prostheses, syringes, catheters, etc., mainly including polyethylene, polypropylene, PVC, and polycarbonate.

• Polyethylene is impact-resistant and corrosion-resistant, making it suitable for prosthetics.
• Polypropylene is fatigue-resistant and suitable for syringes and connectors.
• PVC is strong and durable and is often used in hemodialysis equipment and catheters.
• Polycarbonate is heat resistant and suitable for medical parts such as IV connectors.

What Materials Are Best for Custom Aerospace Parts and Accessories?

Aluminum, magnesium, titanium and nickel-tungsten alloys are widely used in aerospace, automotive and mechanical engineering due to their excellent low density and structural strength, whether by 3D printing or CNC processing. In particular, they occupy a very important position in the aerospace industry and are the main structural materials. Commonly used materials include aluminum alloys (such as A380, ADC12), titanium alloys, magnesium alloys, etc. These materials need to have the characteristics of lightweight, high strength, and high temperature resistance.
These materials are both high-performance and cost-effective, and are ideal for medical applications or aerospace applications.

XY-Global’s Aluminum Die Casting Services

XY-Global is a leading aluminum die casting manufacturer in China, serving the medical, aerospace and other industries. In the past decade, we have produced a variety of aluminum die casting products for our customers, including motor housings, satellite and spacecraft components , die-cast heat sinks, exhaust fans, laparoscopic fixtures , antenna support plates , etc. Our most popular aluminum die casting alloys are ADC12 , A380 , Al-Si8Cu3 , AlSi10Mg(Fe) , AlSi11Cu2(Fe) , AlSi9Sr , AlSi9MnMoZr .

Aluminum die casting alloys in stock

• Aluminum Casting Alloy – Die Casting Aluminum ADC12

ADC12 is an Al-Si-Cu based cast aluminum alloy with excellent casting properties and high mechanical strength. It is often used to manufacture complex automotive parts such as gearboxes, cylinder blocks and torque converter housings. The alloy is widely used in a variety of die castings internationally.

• Die Casting Aluminum Alloy – A380 Aluminum Die Casting

A380 is one of the most widely used die casting aluminum alloys, suitable for a variety of applications due to its excellent properties. It combines excellent mechanical properties, casting properties and thermal properties, with good pressure resistance, fluidity and resistance to hot cracking. A380 is widely used in products such as die casting aluminum radiators, engine brackets, electronic equipment chassis, household furniture, gearbox housings and hand tools.

• Magnesium alloy materials

Magnesium alloy is an alloy composed of magnesium and other elements. Its characteristics are: low density, high specific strength, large specific elastic modulus, good heat dissipation, good shock absorption, greater impact load bearing capacity than aluminum alloy, and good resistance to organic and alkali corrosion. The specific gravity of magnesium is about 2/3 of aluminum and 1/4 of iron. Therefore, it is widely used in mobile phones, communication equipment and other electronic equipment, auto parts, and medical equipment .

At present, the most widely used is magnesium aluminum alloy, followed by magnesium manganese alloy and magnesium zinc zirconium alloy. Common grades used are AZ91D, AM60B, AM50A, AS41B, etc.

• Zinc alloy material

Commonly used zinc alloys include alloys 2, 3, 4, 5, and 7. Currently, alloy 3 is the most widely used. The molten state of zinc alloy has very good fluidity and a low melting point of only 365 degrees. Various post-processing treatments can be performed, such as electroplating.

2. Mould development

• Mold design: According to the part design requirements, product molding mold flow analysis, design high-precision molds, consider key factors such as shrinkage, cooling system, pouring gate, etc.

1. High-precision Molds: The design and manufacture of die-casting molds are the key to ensuring product accuracy. High-precision CNC machine tools are required for mold processing, and mold surface treatment (such as chrome plating, nickel plating) can extend the service life and improve the surface quality of parts.

• Mold Manufacturing: Use high-strength mold steel to manufacture molds, and use CNC processing and other high-precision processes to process the details of the molds

1. Die casting molds must be made of hot working die steel. Commonly used steels are: H13, 2344, 8407, 8418, SKD61, DAC, FDAC, etc.

• Mold Testing and Debugging: Through mold testing and flow channel optimization, ensure that the accuracy and consistency of parts after molding meet the requirements
• Mold Maintenance: Regularly maintain the mold to prevent wear or deformation from affecting part accuracy

2. Mould Processing Equipment: milling machine , CNC machining center , wire cutting (slow wire) , (mirror) spark machine , grinder, lathe , mould clamping machine
3. Die Casting Production Process

• Equipment Preparation : We use LK 280-1600 ton cold chamber die casting machines. These machines are equipped with high-precision pressure control systems that can maintain stable pressure during the injection process, ensure casting quality, and reduce part defects.
• Mold Preheating and Cleaning : Preheat the mold before production to reduce thermal shock, extend mold life, and ensure part surface finish
• Die Casting Process Parameter Setting : set appropriate pressure, temperature and cooling time to ensure a balanced temperature field, ensure rapid molding of castings and ensure product accuracy, and achieve a virtuous cycle of production

4. Quality Control

• In-process Inspection and Size Inspection : Use X-ray flaw detection for internal sand holes and shrinkage cavities , CCD visual inspection, three-coordinate measuring machine and other equipment to ensure that each part meets strict quality standards.
• Process Monitoring System: real-time monitoring of key production parameters (such as temperature, pressure), and ensuring process stability through SPC (statistical process control.
• Quality Inspection: Use three-dimensional coordinate measuring machine (CMM) to carry out high-precision inspection on the produced parts to ensure that they meet the design requirements .
• High and Low Temperature Test : ensure that the product does not deform when subjected to alternating hot and cold conditions

5. Post-processing and Quality Inspection

1. Flushing Nozzle : The die-cast products need to cut off the head and nozzle, and remove most of the excess material
2. Correction: After the die casting is deformed, it can be corrected manually or mechanically. This correction process is called correction. Correction is divided into hot correction and cold correction .
3. Thread Hole Processing : Structural parts basically require thread hole processing. Different drill bits and taps should be selected according to the different specifications of the threads.
4. Turning/CNC Machining: Due to the limitations of die-casting molds and process technology, some structures and dimensional precision cannot be achieved by die-casting, so machining is required.
5. Grinding to Remove Burrs: Due to the limitations of die-casting molds and process technology, the surface oxide of the product affects the adhesion and appearance of the surface treatment, and it is necessary to add a grinding process to remove burrs on the parting line, cracks and erosion marks caused by mold aging, and burrs caused by CNC processing. At this time, grinding is also required.
6. Surface Treatment : Aerospace and medical device parts usually require additional surface treatment, such as anodizing, electroplating, passivation, etc., to ensure the corrosion resistance and aesthetics of the product.

• Polishing​

Our factory uses robotic arm automation technology to achieve efficient operations throughout the entire process from grabbing, polishing to putting down, greatly improving post-processing efficiency. As a manufacturer of precision new energy housing accessories, we ensure the high quality and consistency of each product to meet the industry’s strict requirements for precision and efficiency.

• Special process of friction welding – comparison before and after production and waterproof test

Friction stir welding (FSW) is an advanced welding process that uses rotating tools to generate frictional heat at the joints of workpieces to plastically connect materials, avoiding the melting problem in traditional welding. It can achieve high-strength, pore-free welding effects, and is especially suitable for materials such as aluminum alloys. The comparison pictures before and after production clearly demonstrate the outstanding advantages of this process: the welding joint is smooth and uniform, and the strength is significantly improved, providing reliable guarantee for high-demand manufacturing.

After friction stir welding, the product must also undergo a rigorous airtightness test to ensure that the welded joint is completely leak-free. This step is crucial for demanding applications, especially in parts that need to prevent gas or liquid leakage. The airtightness test can further verify the welding quality and ensure the long-term reliability and safety of the product in actual use.

After friction stir welding

Powder coating : By evenly spraying the powder coating, the product not only obtains a smooth surface, but also enhances its corrosion and wear resistance. The powder coating process can effectively cover complex shapes, ensuring that every detail is protected. After the curing process, the coating is firmly attached, giving the product lasting beauty and functionality.

Note: Factors affecting product prices:

01 Product weight : die-cast product weight and material characteristics (unconventional aluminum ingots start at 20 tons, and die-casting production schedules are long).

02 Product structure : Does the die-casting product structure have a demoulding angle? If there is no demoulding angle, the mold structure needs to be increased and CNC processing needs to be added.

03 Product accuracy: Die-casting product structure and dimensional accuracy. Product accuracy will affect CNC processing time and clamping times.

04 Appearance requirements: The appearance requirements of die-cast products and the internal sand hole requirements will affect the yield and loss of the process. The clearer the drawing requirements, the higher the quotation fit will be.

05 Usage scenarios: die-casting product usage scenarios, special requirements such as mechanical properties and aging and corrosion resistance.

06 MOQ quantity: the number of processes. The more processes, the higher the process loss. MOQ batch quantity, because the die casting process is a mass production process, the quantity will also affect the unit price of the product.

6. Batch production strategy

Automated production line : Relying on the automated equipment of the die-casting island of the LK die-casting machine , we have achieved fully automated continuous production, greatly reducing manual operation errors and improving production efficiency and product consistency.

Multi-cavity molds: Multi-cavity molds enable mass production while ensuring consistent dimensional accuracy of each cavity.

7. Quality certification and compliance review

Working with suppliers with ISO 13485 (medical devices) and ISO9001 quality certifications ensures that products consistently meet strict industry standards during mass production.

Batch records and traceability: Establish a complete production record and traceability system to ensure the traceability of each batch of products

8. Logistics and Supply Chain Management

• Supply Chain Optimization : Ensure a stable supply of raw materials such as die-casting materials and accessories to avoid production interruptions and ensure continuous operations.
• Inventory Management : Use advanced inventory management systems to maintain an appropriate amount of inventory, ensure parts are delivered on time, and reduce inventory costs.
• Global Delivery : By optimizing logistics processes, we ensure that large quantities of die-cast parts are delivered to global customers on time, improving customer satisfaction.

9. Continuous improvement and feedback optimization

• Customer Feedback Analysis : Collect and analyze customer feedback to continuously improve product quality and optimize production processes to meet customer needs.
• Technology Update : Keep up with industry development trends, regularly upgrade die-casting technology and equipment, improve production efficiency and part precision, and ensure the company’s technological leadership.

Need aluminum die castings manufactured in batches and post-processed? XY-GLOBAL is one of the best aluminum die casting companies and we are pretty sure we can help you.

If you have die casting parts for medical , aerospace, semiconductor and optical fields please send us your drawing inquiry to market@xy-global.com for further evaluation. Here, we provide one-stop manufacturing services to meet your aluminum die casting needs!