Aluminum Die Casting Automotive Housing

The customer required a lightweight yet structurally strong housing for an electric vehicle control system. The part featured complex internal geometries, thin wall sections (as low as 1.5 mm), and multiple precision mounting points.

Key challenges included:

– Maintaining dimensional accuracy for tight tolerance features (±0.05 mm)
– Avoiding porosity and air traps in critical sealing areas
– Achieving a smooth surface suitable for subsequent powder coating
– Ensuring consistent quality across high-volume production
– Integrating multiple functional features into a single die-cast part to reduce assembly

Additionally, the project required strict timeline control to support the customer’s product launch schedule.

To address these challenges, our engineering team implemented a comprehensive die casting solution:

– Optimized mold design with advanced gating and venting systems to minimize porosity
– Simulation analysis (flow and solidification) to improve metal distribution and reduce defects
– Use of high-pressure die casting (HPDC) for consistent part density and structural integrity
– Precision CNC machining applied to critical surfaces and threaded holes
– Post-processing including deburring, shot blasting, and powder coating preparation

We also established a strict quality control plan, including first article inspection (FAI) and in-process dimensional checks, ensuring stable mass production.

Close communication with the customer allowed rapid iteration and approval of initial samples within a short development cycle.

The project was successfully delivered with excellent performance and customer satisfaction:

– Reduced part weight by 18% compared to the previous steel design
– Achieved dimensional tolerance within ±0.05 mm for critical features
– Surface quality met coating requirements without additional rework
– Production yield rate exceeded 98%
– Lead time reduced by 30% through optimized tooling and process control

The final solution enabled the customer to improve product performance while lowering overall manufacturing costs.

This project demonstrates our capability in delivering high-quality die casting solutions for demanding automotive applications.