Custom die casting Aluminum Furniture parts Solutions
1.confirm the 3D drawing
When the customer sent us the product drawings, we found that the solid product would be very heavy. The small one weighs 1 kg, and the long leg weighs 8.5 kg, as shown in figures 1.1 and 1.4.
According to the drawings, it will take a lot of materials to make it solid, so it will take up a lot of material costs and need to be optimized. We suggest that it can be made hollow. We explained this situation to the customer, and the customer also agreed with our idea, we need to lower the weight to reduce material costs and product costs but not affect the performance of the product. This is also more conducive to market promotion.
Then we tried to make it hollow from a solid product. We needed to evacuate the inner cavity first, and at the same time ensure that the wall thickness is 3mm without affecting the product function, as 1.2 and 1.5 shown. In addition, we needed to add 2 reinforcing ribs to enhance the stability of the product. After continuous attempts and modifications, we finally reached the ideal state. It took a total of 1 week to modify the drawings. The final plan was determined, as 1.3 and 1.6 shown.
1.1 Initial Clement Head Backup-1.5kg
1.2 Clement Head Backup--hollow
1.3 Clement Head Backup with 2 reinforcement ribs--0.52kg
1.4 Initial furniture leg-solid 8.5kg
1.5 Furniture leg-hollow
1.6 Furniture leg with 2 reinforcement ribs-2.85kg
2.2. Mold design.
Based on the final product drawings, we determined the die casting process and then began to design the mold. During this process, we thought of using sliders to achieve the hollow effect.
Especially for the furniture legs, the size is 660x120x70mm, which is very deep. The slider can no longer meet the needs, so we thought of using the hydraulic cylinder method to pull the core. Although the cost of using the hydraulic cylinder will increase, it is very worthwhile for the long-term progress of the project. 2.1-2.4 pictures are simple diagrams of the mold.
2.1
Clement Head Backup mold drawing with hydraulic cylinder
2.2
Furniture leg mold design with Hydraulic Cylinder
2.3
Clement Head Backup mold drawing structure
2.4
Furniture leg mold design drawing structure
3. Make the mold
After the mold drawing was confirmed, we purchased H13 mold steel within 3 days and then sent it to the processing center.
CNC milling: Use 3-5 axis CNC mills to machine core and cavity inserts with tight tolerances (±0.01 mm). Cut cooling channels (waterlines) and ejection pinholes.
EDM: Employ wire EDM for intricate shapes or tight corners. Sink EDM creates detailed textures or undercuts using custom electrodes.
Drilling and Tapping
Heat Treatment: Quench and temper the mold parts.
Component Cleaning: Clean all parts to remove machining residues.
Precision Fit: Assemble cores, cavities, slides, and ejector systems, ensuring seamless alignment.
Hydraulic/Pneumatic Integration: Install cylinders for slide actions and cooling connectors.
Conduct trial runs with molten metal to validate performance, adjusting for defects like porosity or misalignment.
After about 30 days, the upper mold and the lower mold were completed.
4. Mold assembly and die casting
It took a day to debug the machine, after the mold is assembled and tested without any problems, we began to produce, put it on the 800-ton machine for processing.
5. Finished product display
The net weight of small products can reach 0.53 kg, and the large products can reach 2.85 kg.
The furniture leg with ribs is black powder coated, the customer is very satisfied with 2 products.
5.1 aluminum die casted head backup
5.2 aluminum die casted head backup in another view
5.3 aluminum die casted furniture leg with ribs
5.4 aluminum die casted furniture leg with ribs in another view
5.5 aluminum die casted furniture leg with ribs in black powder coated
5.6 aluminum ADC12 die casting furniture leg with ribs
Conclusion
Based on our latest optimized solution, the net weight of small products has been reduced to 0.53kg, while that of large products has been minimized to 2.85kg.The significant reduction in product weight has resulted in significant cost savings through reduced material consumption as well as potential transportation and processing costs. As a result, our customers have expressed high satisfaction with the end result and recognized the effectiveness of our proposed solution in improving product efficiency and economic viability.