Precision Die Casting Mold Manufacturing Experts

KINGMETAL Mold Manufacturing Process

• Design & Engineering

  Our mold engineers utilize UG NX and SolidWorks for 3D mold design, performing thermal simulation with MAGMASOFT® to optimize cooling channel layout and predict filling behavior. All designs undergo DFM analysis to ensure manufacturability.

• Precision Machining

  Core manufacturing process using advanced CNC equipment:

  Rough machining of mold bases on large-bed mills

  Semi-finishing with high-speed machining centers

  Electrode manufacturing for EDM operations

• Electrical Discharge Machining (EDM)

  Complex cavity and core details are machined using:

  Sinker EDM for intricate shapes

  Wire EDM for precision contours

  Small-hole EDM for cooling channels

• Surface Finishing & Texturing

  Critical surfaces are finished to precise specifications:

  Hand polishing to SPI A1 standard (Ra 0.012μm)

  CNC polishing for consistent results

  Laser texturing for custom surface patterns

• Assembly & Validation

  Final integration and testing:

  Precision assembly in temperature-controlled environment

  3D scanning for dimensional verification

  Trial run with actual casting material

Advanced Manufacturing Equipment

• Large CNC Machining Centers

  Makino A101 (2000x1200x1000mm)

  DMG MORI NHX 6300 (1600x1000x800mm)

  Positioning accuracy: ±0.005mm

• High-Speed EDM Systems

  Sodick AQ550L sinker EDM

  Mitsubishi MV2400S wire EDM

  ±0.003mm machining accuracy

• Precision Grinding Machines

  Okamoto CNC surface grinders

  Studer cylindrical grinders

  Flatness tolerance: 0.002mm/300mm

• Measurement & Inspection

  Zeiss CONTURA G2 CMM

  Keyence laser scanners

  Mitutoyo coordinate systems

• Material Capabilities

  All materials are vacuum hardened and tempered to achieve optimal hardness (46-50 HRC) with deep hardening characteristics.

  Component Type	Standard Materials	Premium Options
  Cavity & Core	H11, H13 (1.2344)	DIEVAR, QRO 90 Supreme
  Inserts & Pins	1.2343, 1.2367	Vanadis 8, Caldie
  Mold Base	1.2312, P20	1.2738 HH

• Company Capabilities & Certifications

  Manufacturing Scale: 15,000 ㎡ facility with dedicated mold manufacturing area

  Annual Capacity: 100+ medium/large molds (up to 30 tons)

  Engineering Team: 15+ mold specialists with average 12 years experience

  Quality Certifications:

  IATF 16949:2016 Certified

  ISO 9001:2015 Certified

  NADCA #207-2018 Compliant

  Specialized Departments:

  Dedicated hot runner system integration

  In-house heat treatment facility

  Mold maintenance and repair center

• Technical Specifications

  Contact our tooling engineering team to discuss your project requirements:

  Parameter	Capability
  Max Mold Size	2500x1800x1000mm (LxWxH)
  Max Mold Weight	30,000kg
  Dimensional Accuracy	±0.015mm for critical features
  Surface Finish	SPI A1 (Ra 0.012μm) to textured finishes
  Lead Time	10-16 weeks for standard molds

Frequently Asked Questions

• Q: What is your typical mold delivery time?

  A: Standard mold delivery is 10-16 weeks depending on complexity. We offer accelerated services that can reduce lead time by 30% for urgent projects. Critical path is always shared with clients for transparency.

• Q: How do you ensure mold longevity for high-volume production?

  A: We employ a three-pronged approach: 1) Material selection based on application (premium steels for abrasive alloys), 2) Precision heat treatment to achieve 46-50 HRC with deep hardness, 3) Advanced surface treatments including PVD coatings for soldering resistance.

• Q: Can you handle complex conformal cooling designs?

  A: Yes, we specialize in conformal cooling solutions using our Sodick AQ550L EDM machines capable of creating cooling channels as close as 0.8mm to cavity surfaces. Our design team optimizes channel layout using MAGMASOFT® thermal simulations.

• Q: What file formats do you accept for mold design?

  A: We accept all major CAD formats including STEP, IGES, Parasolid, and native SolidWorks/UG NX files. For best results, we recommend STEP AP214 format with complete product specifications.

• Q: Do you provide mold maintenance services?

  A: Yes, our dedicated maintenance center offers complete services including: 1) Preventive maintenance programs, 2) Component refurbishment, 3) Surface reconditioning, 4) Hot runner system repair. Average turnaround is 2-3 weeks.

• Q: What quality assurance processes do you have?

  A: Our IATF 16949 certified system includes: 1) First article inspection reports (FAIR), 2) CMM verification of critical dimensions, 3) Mold flow analysis documentation, 4) Actual casting sample validation, 5) Comprehensive test run reports.