Automobile parts

As integrated die-casting technology is being widely adopted by major automakers such as BYD, NIO, and Geely, automotive body structural parts are shifting from traditional "stamping + welding" processes to large-scale thin-wall integrated die-casting. For mold manufacturers, this is a critical challenge centered on thermal control.

Integrated die-casting parts often exceed 1.5 meters in size, yet local wall thickness must be controlled within 2 millimeters. During the long-distance filling process, high-temperature aluminum alloy is highly prone to defects such as gas entrapment and shrinkage porosity. Meanwhile, under repeated exposure to aluminum melt exceeding 650°C, thermal fatigue-induced cracking directly determines mold lifespan—the difference between 80,000 and 50,000 shots translates into cost gaps measured in millions of yuan.

Shenzhen Haina Precision Mould Co., Ltd. has recently undertaken multiple new energy vehicle structural part die-casting mold projects, covering integrated rear floor panels, front cabin assemblies, and battery pack enclosures. The technical team engages deeply during the product design phase, optimizing wall thickness distribution and draft angles through DFM analysis to mitigate casting risks at the source.

In terms of mold design, the core strategy centers on three approaches: optimizing the gating system through mold flow analysis software to reduce trial runs to within four attempts; introducing high-vacuum die-casting technology to maintain cavity vacuum levels stably below 50mbar, reducing porosity; and utilizing 3D-printed conformal cooling channels to shorten cooling time by approximately 30% while effectively minimizing thermal stress deformation.

The ultimate goal of this approach is clear: help customers achieve 10%–15% weight reduction per casting, over 15% reduction in overall production costs, and 20%–30% shorter development cycles, while extending the stable service life of large die-casting molds to 80,000–100,000 shots.

The first half of the integrated die-casting race is about equipment tonnage; the second half is about mold precision and longevity. Those who lead in thermal balance management will secure the competitive edge in the lightweight race.