Capability 02 — Die Casting

High-Pressure Aluminium Die Casting

ISO 9001:2015 certified aluminium die casting unit with 120T to 660T cold-chamber HPDC machines, dedicated tool room, and precision CNC/VMC machining cells engineered for thin-walled, low-porosity, high-repeatability industrial components.

0.1g–6.0kg

Part Weight Range

120T–660T

HPDC Machine Array

675 MT/yr

Annual Capacity

Min 1.25mm

Wall Thickness

ISO 9001

TÜV SÜD Certified

Manufacturing Scope

Core Processes

→High-Pressure Die Casting (HPDC) — Cold-chamber casting cells from 120 Ton to 660 Ton clamping force
→Electric Melting & Holding — 5× Electric melting and holding furnaces with real-time temperature control
→Hydraulic & Power Trimming — 20T hydraulic trimming presses & 10T power press for clean flash removal
→Precision CNC / VMC Machining — Haas VF-2 (USA) & BFW machining centres with positioning accuracy up to 0.003mm
→CNC Turning & Secondary Operations — Twin-axis CNC turning (travel up to 600mm), drilling, tapping & grinding
→Tool Room & CAD/CAM Engineering — In-house DFM analysis, die manufacturing support, and rapid prototyping
→Surface Finishing & Deburring — Vibro-deburring, shot blasting, and protective surface coatings

Technical Parameters

Engineering Specifications

Aluminium AlloysADC12, LM24, LM6, A380, AlSi9Cu3 & Custom Alloys
Casting Weight Range0.100 grams to 6.000 kg
Wall Thickness LimitsMin 1.25 mm to 2.0 mm (thin-wall capability)
Annual Production Capacity675 MT / Annum (25 Tonnes / Month)
Annual Production Volume10,000 to 500,000 pieces / part / year
HPDC Machine Fleet120 Ton (×2), 180 Ton (×1), 250 Ton (×1), 660 Ton (×1)
Production Melting Furnaces5× Electric Melting & Holding (500kg×1, 250kg×2, 400kg×2)
Trimming Press Array20 Ton Hydraulic Trimming (×2), 10 Ton Power Press (×1)
VMC Work EnvelopeBFW (1050×650×610mm), Haas VF-2 (765×406×508mm)
Machining AccuracyPositioning 0.003–0.005mm · Repeatability 0.003mm (ISO 230-2)
Quality CertificationsISO 9001:2015 (TÜV SÜD), ZED Silver, Lean Intermediate

Infrastructure Overview

HPDC Casting, Machine Shop & Tooling Setup

Modern automated casting cells and tight-tolerance CNC machining centres built for scalable volume production.

Unit 01 · Casting Fleet

HPDC Casting Shop

Cold-chamber High-Pressure Die Casting array capable of casting thin-walled enclosures and heavy structural housings.

▸660 Ton HPDC Machine: 1 no. for large motor housings & structural parts
▸250 Ton HPDC Machine: 1 no. for medium electrical enclosures & cases
▸180 Ton HPDC Machine: 1 no. for high-speed precision valve bodies
▸120 Ton HPDC Machines: 2 nos. for intricate small components & hubs
▸Electric Melting Furnaces: 5 nos. holding units (500kg, 250kg×2, 400kg×2)
▸Trimming Presses: 2× 20T Hydraulic Trimming & 1× 10T Power Press

Unit 02 · Machining Fleet

Precision Machine Shop

Multi-axis vertical machining centres and CNC turning centres delivering micron-level positioning and fine surface finishes.

▸Haas VF-2 VMC (USA): Travel 765×406×508mm, 0.003mm repeatability
▸BFW 60 T20 VMC: Travel 1050×650×610mm, 0.012mm repeatability
▸CNC Turning Centres (RIT 600 T): 2 nos., Travel X:350mm, Z:600mm, 0.003mm positioning
▸Conventional Machinery: Precision Lathes, Pillar Drills & Radial Drills
▸Cutting & Sizing: Heavy-duty Bandsaw Cutting Machines & Power Presses

Unit 03 · Engineering

Tool Room & DFM Support

Complete lifecycle engineering from 3D CAD/CAM modeling and mold flow analysis to die manufacture and prototyping.

▸CAD / CAM Design Support: 3D part modeling, parting line & gating optimization
▸Die Manufacturing Support: Hardened tool steel dies with extended shot life
▸Rapid Prototyping: Quick-turn sampling for functional testing and fitment
▸Finishing & Deburring: Vibro-polishing, mechanical deburring & degreasing
▸Assembly & Dispatch: Component sub-assembly, export packaging & logistics

Zero-Defect Quality

Inspection & Testing Capabilities

Rigorous quality gates covering raw alloy ingot verification, dimensional validation, and pressure tightness.

01 Dimensional Accuracy & Metrology

✓3D Coordinate Metrology: Coordinate Measuring Machine (CMM) verification for critical GD&T
✓Surface Roughness Analysis: Precise measurement of Ra & Rz surface parameters
✓Height & Depth Metrology: 2D digital height gauges and precision bore micrometers
✓Gauges & Fixtures: Custom go/no-go plug gauges, ring gauges & dedicated clamping jigs
✓Full Traceability: Batch heat tracking and raw material test certificates (MTC)

02 Material Testing & Pressure Integrity

✓Chemical Composition: Optical emission spectrometry testing of aluminium alloy melt
✓Hardness Testing: Standard Webster and Rockwell hardness testing
✓Hydrostatic & Pneumatic Leak Testing: Dedicated air/water pressure test fixtures for leak-proof valve bodies
✓Cleanliness Analysis: Millipore gravimetric particulate testing for automotive parts
✓ISO Certified Management: TÜV SÜD certified ISO 9001:2015 & ZED Silver compliance

Component Scope

High-Pressure Aluminium Die Casting

Core Processes

Engineering Specifications

HPDC Casting, Machine Shop & Tooling Setup

HPDC Casting Shop

Precision Machine Shop

Tool Room & DFM Support

Production Process Flow

Inspection & Testing Capabilities

01 Dimensional Accuracy & Metrology

02 Material Testing & Pressure Integrity

Industry Applications & Products

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Sheet Metal

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