MingSheng Hardware Manufacturing

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SAND AND DIE CASTING MOULDING

Sand Moulding

Die Casting Moulding

Moulds Making Process

Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand as the mold material. The term "sand casting" can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries. Over 70% of all metal castings are produced via sand casting process.

Molds made of sand are relatively cheap, and sufficiently refractory even for steel foundry use. In addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand. The mixture is moistened, typically with water, but sometimes with other substances, to develop the strength and plasticity of the clay and to make the aggregate suitable for molding. The sand is typically contained in a system of frames or mold boxes known as a flask. The mold cavities and gate system are created by compacting the sand around models called patterns, by carving directly into the sand, or by 3D printing.

Die casting is a manufacturing process that can produce geometrically complex metal parts through the use of reusable molds, called dies. The die casting process involves the use of a furnace, metal, die casting machine, and die. The metal, typically a non-ferrous alloy such as aluminum or zinc, is melted in the furnace and then injected into the dies in the die casting machine. There are two main types of die casting machines - hot chamber machines (used for alloys with low melting temperatures, such as zinc) and cold chamber machines (used for alloys with high melting temperatures, such as aluminum). In both machines, after the molten metal is injected into the dies, it rapidly cools and solidifies into the final part, called the casting. The steps in this moulds making process are described in greater detail in the next section.

Aluminum Die Casting provides casting parts with complex shape, thin walls and nice surface finish. This helps minimize follow-up machining and finishing operations. Typically a die casting mold is expensive, but the unit production cost is very economical; Zinc die casting uses hot chamber die casting, so it can be manufactured faster than aluminum die castings which uses cold chamber.

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You’ll enjoy the benefits of much lower costs while still receiving full service injection and die-casting molded solutions from start-to-finish with MingSheng Hardware Manufacturing.

Our Process:
Step 1: Request for Quotation Send Design Drawings, 2D part drawing, 3D drawing, specific mold & part requirement, or Prototype samples. (Solidworks, IGES, AutoCAD); Design softwares: UG, Pro-E, Master cam, Solid works, 3D max, AutoCAD, CAM; Drawing format( 2D file - dwg, dxf/pdf, jpg), 3D model format( igs, x_t, prt).
Step 2: Technical and engineering Discussion and Quotation(3 Days) Understand your critical requirements through effective communication and technical requirements set up.
Step 3: Make Molds and Submit Sample Up on confirmation from clients, we can produce samples with moulds made to ensure quality and meet requirements before mass production. Timeline: 25 - 45 days depends on complexity and requirements For urgent orders, we offer expedited mold making (10-15 Day)
Step 4: Mass production Mass production can be initiated up on clients’ confirmation of sample. Consistent quality is maintained by regular checking of products and mold condition. We welcome client visits at any stage.
Step 5: Quality control Quality will be ensured with consistency of samples provided.
Step 6: Shipping and Delivery Clients can choose their preferred logistics partners or we can arrange with our own logistics partners with several options.

Notes:
1. Sometimes, our clients have multiple parts to be made and require parallel injection or die-casting moulds making. We have the capability of parallel moulds making and resources can be easily expended and planned according to clients’ early notice.
2. Steel and standard mold components: P20, S136, NAK80, SKD61, 420SS. The standard components from LKM, HASCO (for export mold), DME (for export mold). For hot runner systems, we often use YUDO, MOLDMASTER, HUSKY, INCOE.
3. Payment Terms: Mould Payment terms: 50% - 25% - 25%; Part payment terms: 40% - 60%;
4. Quality Assurance Policy Within quality criteria at each stage of mould production, we will be responsible for any products quality issues, and we will replace or compensate at our expense if our product doesn’t meet agreed requirements.

ALUMINUM ALLOY DIE CASTING SERVICE

Alumilum Alloy

Benefits of Aluminum Alloy

Aluminum Alloy Product Application

Frequently used materials: A356, A360, A380, A390, A383, A413, AlSi10Mg, ADC-12, ADC-14, LM4, LM6, LM9
Standards: ASTM B85 Die Castings
A356 is the most popular. A380 aluminum alloy is also widely used for casting general-purpose die castings.

Aluminum dia casting alloy has many different advantages, such as lightweight, good corrosion resistance and mechanical properties, high thermal and electrical conductivity and etc., enabling it to be applied in many areas, including consumer, commercial and industrial products. Often times, it is very important component of products like automobiles, computers, washers, dryers, refrigerators, furnaces and so on.

Aluminum Alloy Advantages:

1. Complex shapes with mass production
The aluminum die casting can provide complex shapes within closer tolerances, little or no machining is required after an aluminum part is die cast, because the process provides very close tolerances. It is much more efficient than than other mass production materials and processes to produce thousands of complex identical casting in limited time.
2. Very good corrosion resistance
3. Excellent strength and hardness
4. Very good thermal and electrical conductivity
5. Low density and light-weight
6. High dimensional stability and relative easy to cast
7. Recyclable & Non-Magnetic

Modern Aluminum Die Casting Machines ranging in size from 600 ton to 1750 ton produce castings for a broad variety of industrial market sectors:

  • Off-Road Equipment
  • Lawn and Garden
  • Automotive
  • Computer Hardware
  • Metering Devices
  • Telecommunications
  • Industrial Lighting
  • General Engineered Castings
  • Power and Hand Tools
  • OEM aluminum die casting for LED light part
  • Aluminum die castings for car accessories
  • Other specific industrial design requirements

ZINC DIE CASTING SERVICE

Zinc Alloy

Benefits of Zinc Alloy

Zinc Alloy Finishing Options

Zinc Alloy Products Application

Frequently Used Zinc Die Castings Materials: Zamak ZA3, ZA8, ZA12, ZA27, Zinc alloy 2, 3, 5, 7

Zinc Alloys: Zinc-based alloys are the easiest to die cast. Ductility is high and impact strength is excellent, making these alloys suitable for a wide range of products. Zinc alloys can be cast with thin walls and excellent surface smoothness making preparation for plating and painting relatively easy. It is essential that only high purity (99.99 + 0/0) zinc metal be used in the formulation of alloys. Low limits on lead, tin and cadmium ensure the long-term integrity of the alloys strength and dimensional stability.

Zinc Die Cast Advantages: Zinc casting alloys are strong, durable and cost effective engineering materials. Properties of zinc alloys can compete with and often exceed those of cast aluminum, magnesium, bronze, plastics and most cast irons. Also, the finishing capabilities of zinc alloys make it much more popular than many other options for industrial hardwares and accessories.

The Top Benefits of Zinc Alloy as Die Casting Materials:

1. Superior casting fluidity and strength.
Zinc alloy’s superior casting fluidity and yield strength over aluminum makes zinc-based products permits the design of thinner and more precise wall sections for reduced wright and material cost than aluminum alloys. And, it is much easier to be assembled, the entire assemblies can be cast as a single unit, eliminating the need for expensive manual assembly operations.
2. Extended Tool Life
The tools for zinc die cast components have exceptionally long lives. And die-cast manufacturing rates for zinc are much faster than for aluminum, or magnesium. Coupled with a tool life often exceeding 1 million casting cycles, tooling and machine usage charges are dramatically reduced, whereas an aluminum tool will typically only last 100,000 to 200,000 shots. For parts with high volumes, zinc will always be a money saver in tooling costs.
3. Great for High Volumes Production
Hot chamber die casting is the process that all zinc die casters use. It’s different than cold chamber die casting because there is no pouring of the molten metal into the gooseneck. This makes hot chamber much faster because the metal comes directly from the chamber underneath and there’s no wait time for filling.
4. Variety of Finishing Options
Comparing to other metal and alloy materials, unlike aluminum castings usually have to be buffed before they can be finished which represents a significant increase in processing costs, zinc alloys with a much smoother surface and are much less expensive and easier to finish with a variety of finishing options. Zinc is suitable for a variety of finishing options for cosmetic and anti-corrosion purposes, including: electroplating, overmolding, powder coating, chrome plating, PVD (physical vapor deposition) and CVD (chemical vapor deposition).
5. Excellent Thermal Conductivity
Zinc is an excellent conductor of temperature. This makes it a great material for heat sinks in certain applications.
6. Perceived Quality
Weight is a property of zinc that can’t be ignored. It’s roughly 2 ½ times heavier than aluminum, which can be a major disadvantage in certain applications, but not in others. If you want to make a product that has thin wall design while achieving high perceived value, zinc is the perfect material. Its density conveys value and quality to any end customer.
7. Sustainability & Green
Zinc die castings can be easily recycled compared to plastic substrates, making zinc a more sustainable manufacturing material. Also, zinc takes less energy to melt because its melting point is only 787.2°F, whereas aluminum’s melting point is 1,221°F. This also gives zinc an advantage over aluminum on the recycling end because it takes less time and energy to melt zinc down than aluminum. Over the course of 2 cycles, zinc would save over 800°F worth of heating energy over aluminum.
8. Net Shape Casting
Casting to net shape means that the casting comes out of the die and doesn’t need to be machined at all. This is extremely advantageous in terms of piece price because fewer machine hours and processing steps translate into a lower the piece price.

We provide a variety of finishing options, painting or plating, for both zinc alloy accessories and hardwares. Some more popular ones:

Die Cast Finishes Available

  • Satin Chrome
  • Bright Brass
  • Satin Brass
  • Oil Rubbed Bronze
  • Satin Bronze
  • Satin Nickel
  • Antique Pewter
  • Satin Blackened Brass
  • Lifetime Finishes - PVD
  • Others up on requirements

Die Cast Finishes Available

  • Vibratory Finishing
  • Thermal De-Burr
  • Powder Coat
  • E-Coat
  • Chromate
  • Decorative Electroplating

With many benefits of zinc alloy materials, such as high density, high ductility, good impact strength, excellent surface smoothness allowing for painting or plating, easiest to cast, can form very thin walls, long die life due to low melting point and use of a hot chamber machine, all these advantages and the zinc hot chamber die casting machines ranging in size from 250 ton to 500 ton produce castings for a broad variety of industrial market sectors:

Conventional zinc die castings range in size from a few ounces to 12 pounds
Logos/Name Plates
Buttons/buckles
Rivet/Labels/Badges
Metering and Control Devices
Lawn and Garden
Commercial Lighting
General Engineered Die Castings
Power and Hand Tools

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FREQUENTLY ASKED QUESTIONS

Please don’t hesitate to contact us for any question you might have. You can send your contact information and enquiries though out contact us page. We will get back to you within 1 business day. Or just email or call us directly. We are always able to assist and answer your questions.

How can I get a sample product?

For customized samples with clients’ specification and design, any customization samples need to be made with moulding. Therefore, clients will be responsible for both moulding, samples and shipping cost.

If we have mold and have no inventory available, then clients will be charged for sample production cost and shipping cost.

Mold fee is based on products’ specification and design, and it is not refundable up on sample order confirmation. Samples production time depends on the specification and requirements.

How do we place an order and receive products?

Our processes can be summarized into the following steps:

Step 1: Request for Quotation. Send Design Drawings, 2D part drawing, 3D drawing, specific mold & part requirement, or Prototype samples. (Solidworks, IGES, AutoCAD); Design softwares: UG, Pro-E, Master cam, Solid works, 3D max, AutoCAD, CAM; Drawing format( 2D file - dwg, dxf/pdf, jpg), 3D model format( igs, x_t, prt).

Step 2: Technical and engineering Discussion and Quotation(3 Business Days) Understand your critical requirements through effective communication and technical requirements set up.

Step 3: Make Molds and Submit Sample up on confirmation from clients, we can produce samples with moulds made to ensure quality and meet requirements before mass production. Timeline: 7 - 45 days depends on complexity and requirements. For urgent orders, we offer expedited mold making.

Step 4: Mass production Mass production can be initiated up on clients’ confirmation of sample. Consistent quality is maintained by regular checking of products and mold condition. We welcome client visits at any stage.

Step 5: Quality control Quality will be ensured with consistency of samples provided. Quality Assurance Policy Within quality criteria at each stage of mould production, we will be responsible for any products quality issues, and we will replace or compensate at our expense if our product doesn’t meet agreed requirements.

Step 6: Shipping and Delivery Clients can choose their preferred logistics partners or we can arrange with our own logistics partners with several options.

How long does it take for mass production?

Depends on the design, specification, quantity and finishing requirements, please send us a inquiry for more details.

Is there minimum order quantity for each order?

This really depends on the design and customized products. We always welcome long-term clients and large transactions. Our clients get the most value out of their transaction when placing large orders. But also, we are flexible with quantity up on requirements. Please don’t hesitate to reach us if you have smaller orders, we will be happy to serve with our capacity.

Could we schedule a factory visit or a remote video conference?

Yes, we always welcome our clients to visit our factory and have an in-person discussion with design and production. Also, we are able to schedule a video conference to better communicate designs and specifications. We always encourage effective communication with our clients to ensure better quality and minimize risks or potential change orders.

How does your company differentiate from many other competitors?

Nowadays, finding a reliable supplier have become harder than ever because of so many available in the market without actual experience and expertise. Our company has been in this industry for more than 15 years. Our technical teams and extensive experiences in mold production, zinc alloy and aluminum alloy die-casting products make us stand out among others. We highly value our clients’ value and always try to work with rather than just work for our clients.

What payment methods do your company accept?

The payment methods we accept are Paypal (less than $1000) and International Wire Transfer.

Payment Terms: T/T; Payment Terms: Mold Payment Terms: 100% up on confirmation; Part Payment Terms: 30% - 70%;

Full payment before shipment for small orders; For large transactions, 30% Deposit before mass production, and 70% before shipment)

What are your shipping options?

The closest port to our factory floor is Shenzhen.

We have several major logistics for international shipments, DHL, UPS, FedEx, and USPS. Most of our shipments are shipped by air, and it usually takes about 3 - 4 business days.

Delivered 3000+ projects over 15 years for our amazing clients, if you interested? Contact Us