ONE-STOP ALUMINUM DIE CASTING MANUFACTURER IN CHINA
- ISO 9001:2015 & IATF 16949:2016 certified aluminum die casting manufacturer
- One-Stop Aluminum Die Casting Service
- Provider 10+ years experience, 4 facilities & 182 professionals
- Our Fast production assures you always on-time delivery
- Welcome High-Mix, Low volume Projects
We customize all orders to suit your budget and business plan so that you can run your production lines smoothly!
ALUMINUM DIE CASTING CAPABILITY
Sunrise Metal offers a wide range of services other than just die casting. The goal of our company is to provide you a one-stop solution for your project. Starting from rapid prototyping to quality surface finishing, Sunrise Metal helps you get the final product with ease and here in one place
Sunrise Metal is committed to making real-life products out of your dreams. When it comes to rapid prototyping, we can deliver you the desired products in ½ the time compared to other manufacturers with the highest quality assurance.
Our high mix and low to medium volume prototyping workshop allow you to have the best output within a very short amount of time. Sunrise Metal is one of the leading companies in this sector when it comes to R&D. Along with advanced technologies, professional and experienced engineers, we ensure that our clients are getting the best service for their projects.
Die Casting Tooling
Our state of the art in-house tooling shop allows us to provide complete solutions from tooling design, manufacturing, modification, and maintenance to tooling end management.
Sunrise Metal has years of experience in die casting tooling, which reflects on your final product, and the quality of the mold. Our rapid tooling service only takes 2-4 weeks or less, depending on your volume and requirements.
The advanced equipment and machines make us capable of providing world-class service in making any molds or tools.
Aluminum Die Casting Production
With 280T to 1600T machines and two specialized die casting facilities, we have the highest capabilities to deliver the best quality parts for our customers. The broad scope of materials, machines, and years of experience help us make the exact product that meets your demand well.
Sunrise Metal has been serving customers worldwide with premium quality parts for more than 10 years. Being one of the leading die casting manufacturers globally, we take 100% responsibility for our products’ quality.
To meet our customers’ demand worldwide, Sunrise Metal equipped 23 sets of CNC Machining Center and 4 CNC Lathe in our die casting shop. This enables us to provide not only the machining for die casting parts but also provide machining from solid, extrusion, gravity casting, forging, etc.
The high-tech engineering and expert workforce allow us to provide a precise and highly accurate CNC machining service according to your requirements.
To give our customers a one-stop solution, we’re providing a world-class surface finishing service to go with the quality of our manufactured parts.
Sunrise Metal aims to meet all our customers’ demands and help you get everything in one place. To do so, we’re now capable of serving you with various high-quality surface finishing options that go with your final products. All our surface treatments are ROHS & REACH compliant.
• Shot Blasting • Powder Coating • Liquid Painting • Electroless Nickel
• Anodization • Silk Screening • Pad Screening • Chromate-Surtec 650
RICH MANUFACTURING EXPERIENCE ON 2500+ ALUMINUM DIE CASTING PARTS
- Die cast Coffee ComponentCoffee Machine Component For Israel Client with Powder Coating
- Die Casted Marine PartMarine Radar Component For UK Client with Powder Coating
- Die Casted Coated PlateNavigation Display Component For UK Client with Powder Coating
- Die casted Engine PipeAutomotive Casting Part For Germany Client with Sand Blasting
- Die Casted Power CoverPower Tool Component For American Client with Powder Coating
- Die Casted BracketDental 3D Scanner Component For Danish Client with Surtec 650
- Die Casted FrameMedical Ultrasound Component For American Client with Powder Coating
- Die Casted Display FrameTelecom Enclosure Component For Canadian Client with Powder Coating
HOW SUNRISE METAL SUCCEED YOUR ALUMINUM DIE CASTING PROJECTS
We hire experienced quality engineers and deploy advanced quality equipment. We take strict quality control for every production process. All we do is to assure the best quality of the products and services we provide to you.
With an average of 10 years’ experienced engineering team, we provide you DFM, engineering support during the whole project life.
We provide you one-stop service integrating Rapid Prototyping, Tooling, Aluminum Die Casting, CNC Machining & Surface Finishings.
ADVANCED ALUMINUM DIE CASTING PRODUCTION EQUIPMENT AT SUNRISE METAL
- Tooling EquipmentHigh precision tooling equipment in-house
- Aluminum Die Casting MachinesDie casting machines ranging from 160T to 1600T
- CNC Machining CentersHigh precision 3 & 4 & 5 & 7 axis CNC machining equipment
- Chromating Production LinesAutomated Cr6+ free chromating cleaning
- Automated Powder CoatingCapable of various colors powder coating
- Electro Plating LinesROHS & Reach compliance plating production
YOU CAN EXPECT STRICT QUALITY CONTROL ON YOUR ALUMINUM DIE CASTING PARTS
- Tooling Quality ControlMold in-process dimension varification
- Spectrum Meter InstrumentMaterial composition checking
- On-site Produciton ControlDie casting process patrol checking each 2H
- X-ray DetectorDie casting porosity & inside defects checking
- On-site Production InpectionRecording sand blasting production checking result
- On-site Leakage InspectionPressure test to ensure parts leakage free
- Carl Zeiss CMM EquipmentHigh precision instrument with automatic scanning
- Projector Measuring Equipment2D demension inspection for parts
- Cleaniness Test EquipmentParticle control on die casted parts surface
- Product Diemension ControlFull dimension measuring for die casted parts
GLOBAL CUSTOMERS VISIT
As a leading aluminum die casting company, Sunrise Metal provides aluminum die casting service worldwide. Many global clients visit Sunrise Metal to check our capability and capacity. Through on-site factory tour, they trust us and award us with more business. To better know our customers’ business needs and products, we also regularly visit our global customers.
Warmly welcome you to visit us.
|Die Casting Tooling WorkShop (Nantong)|
|Grinder||TATUNG-OKUMA||KGS-615AHD||From 380mm to 1600mm||4|
|Lather||Shanghai 2nd Machine||C6250A||1000mm||1|
|EDM||EDM Korea YIHAWJET Taiwan||NA||From 438mm to 1100mm||8|
|CNC||Local Brand||SONYU-SL850||From 850mm to 3015mm||5|
|Wire Cutting||Local Brand||DK7763||800*630mm/1000*800mm||2|
|Milling Machine||Local Brand||QJM-S2||NA||4|
|High-speed Cutting Machine||Local Brand||906148||750mm||1|
|Deep Hole Drilling||Local Brand||DHD-1513||1513mm||1|
|Die Spotting Machine||Nice Dongguan||NC150-1511||1400mm||1|
|EDM/wire cutting Combined Machine||Local Brand||DK7755||550*630mm||1|
|EDM for very small hole||Local Brand||DD703||300*400mm||1|
|3D Laser Scanner||Sikan Hangzhou||HSCAN771||NA||1|
|Kunshan Die Casting WorkShop|
|Die Casting Machine Type||Brand||Ton||Unit|
|Aluminum Die Casting Machines||LK||280T||1|
|Nantong Die Casting WorkShop|
|Die Casting Machine Type||Brand||Ton||Unit|
|Aluminum Die Casting Machines||LK||280T||1|
|CNC Machining Production Equipment|
|2||CNC Machining Center||17|
|3||Fanuc CNC Machining Center||2|
|4||Hass CNC Machining Center||2|
GET A FREE CONSULTATION
If you are looking for a Chinese aluminum die casting manufacturer, contact Sunrise Metal. When you have any hesitation or any design doubt on your aluminum die casting projects, Sunrise Metal Engineering Team can be your free consulter. Sunrise Metal gives suggestions on your custom aluminum die casting parts at 3 aspects:
1. Your design evaluation.
2. Feasibility analysis for mass production.
3. Project time and part’s cost-saving.
Contact us now, to see how we can help you with your Aluminum Die-casting projects.
ALUMINUM DIE CASTING MANUFACTURER：
THE ULTIMATE FAQ GUIDE
Need the best solution for high volume or low to medium volume production of your products? Then you probably need an Aluminum Die Casting Manufacturer. They can give you the best manufacturing solution by balancing the production cost and quality of your parts.
Sunrise metal is a Chinese Aluminum Die Casting Manufacturer with more than 10 years of experience in this field. We pride in our aluminum die casting capabilities, and we are confident to give you a fast and reliable solution for your project.
Aluminum Die Casting
- What is Aluminum Die Casting?
- Why Should I Choose Aluminum Die Casting?
- Why Should I look for an Aluminum Die Casting Supplier Instead of a Zinc or Magnesium Die Casting Supplier?
- What are the Technologies Used by Aluminum Die Casting Manufacturer?
- What are Your Material Options for Aluminum Die Casting?
- How Can Your Company Reduce the Aluminum Die Casting Cost?
- Why Aluminum Die Casting Process is Most Popular in China?
What is Aluminum Die Casting?
Aluminum Die Casting is a widely used metalworking process for producing metal parts with great accuracy and durability. It is one of the most common production methods used by manufacturers all over the world.
Aluminum Die casting is mostly done in a cold chamber machine. The parts are made by injecting fluid aluminum into a die casting mold under high pressure using a plunger. However, there are several steps involved before and after casting the parts.
In order to ensure the highest quality for your parts, it is necessary to execute all the steps involved in mold castings with proper quality control. It is where an experienced and inexperienced manufacturer can play a big role in your project.
Why Should I Choose Aluminum Die Casting?
There are various facts that make aluminum die casting an excellent solution for your products. Let’s have a look at its multitudes of benefits that can greatly enhance your experience with the manufacturing industry.
Aluminum is the third most abundant element and the most abundant metal on earth. About eight percent of the earth’s crust consists of aluminum. Due to the abundance in nature, aluminum is very cheap and available all over the world.
Due to the low cost of raw material, aluminum has become extremely popular in the metalworking industry in a relatively short period.
Aluminum is almost three times lighter than cast iron. This fact alone has been a major driver for preferring aluminum parts. Now developers can make fuel-efficient vehicles. The use of metal in portable goods also became a common scenario as well.
The aerospace industry, in particular, has shown more interest in aluminum die cast parts. Its excellent strength-to-weight ratio makes it the ideal material for this job.
Corrosion Resistance and Wear Resistance
Aluminum die cast parts have exceptional protection against corrosion. It has good wear resistance too. So they are suitable for the corrosive environment and heavy loading conditions. It also minimizes the need for costly surface protection measures.
Increases Production Capacity
Modern die casting methods have made the production of huge volume parts easier than ever. It can produce more parts at a particular time frame when compared against other methods of metalworking. So, it can significantly shorten the project lead time and increase your production capacity.
Enhanced Conductive Properties
Aluminum die castings offer great electrical and thermal conductivity. Aluminum parts exhibit exceptional heat dissipation characteristics, RMI-EFI shielding properties. So, they are extensively used for heat sinks, enclosures of many consumer electronic products.
Why Should I look for an Aluminum Die Casting Supplier Instead of a Zinc or Magnesium Die Casting Supplier?
Aluminum is a more commonly used cast metal for production compared to other non-ferrous metals such as zinc and magnesium. Here I have explained the features of zinc and magnesium die casting to help you decide when aluminum might be a better choice.
Zinc has material properties similar to that of aluminum. It has excellent strength, corrosion, and wear resistance. The raw material cost of zinc is almost equal to that of aluminum. It has a lower melting temperature and easier to cast than aluminum.
But zinc is several times heavier than aluminum. And zinc die casting parts can’t retain strength under high temperatures. So, even with some benefits, zinc is a less preferable option for production. However, zinc is used for producing small parts with intricate details.
Magnesium alloy products are lighter than aluminum, which is a desirable feature for any product. Magnesium parts have excellent machinability as well. But magnesium die casting manufacturers face some production difficulties.
First of all, magnesium parts are costlier than both zinc and aluminum. They are lightweight but tend to buckle under heavy loads. Magnesium is very susceptible to corrosion and wear as well. So, expensive coatings are required for magnesium die-cast parts.
Although there are some special applications for magnesium die cast products in aircraft and sports equipment. But, the slight reduction in weight accompanied by significantly higher production cost and durability issues is not something most preferable by a die casting company.
What are the Technologies Used by Aluminum Die Casting Manufacturer?
There are different aluminum die casting technologies available. Each has its pros and cons. And not all of them are suitable for every task. Different die casting machines may offer better precision, faster production, or support casting of specific materials.
Some of the common aluminum die casting technologies are,
- Low-Pressure die casting
- High-Pressure die casting (Cold Chamber)
- Semi-solid die casting
- Vacuum die casting
- Squeeze die casting
Low-Pressure Die Casting
Porosity is an annoying issue for any die-cast parts. Low pressure die casting is a way of making aluminum parts with reduced porosity. Low-pressure die casting applies additional pressure during the casting. It allows more compact and defect-free parts
But its use is rather limited due to its slower casting cycle, which hampers the production capacity. So, most of the aluminum die casting vendors focus on its faster alternative, the high-pressure die casting.
High-Pressure Die Casting (Cold Chamber)
When you demand high-quality parts and need them fast, high-pressure die casting is what you are looking for. It is more like a standard for aluminum die casting all over the world. That’s why mainly focused on this method in the rest of the guide.
However, there are two high-pressure casting processes, namely the hot-chamber and cold-chamber process. Aluminum has a high melting point. Due to this, it needs to die cast in a separate furnace and carry into the machine with a cold chamber setup.
Semi-solid Die Casting
This aluminum die casting method handles metals that are in between a state of solid and liquid. Metals with such fluidity are called thixotropic fluids. This state of the metal is commonly known as semi-solid. It allows casting aluminum with higher precision.
The semi-solid casting procedure is used for making parts that have delicate applications. Mainly aircraft, medical devices, defense equipment, etc. are produced using the semi-solid die casting method.
Vacuum die casting is an improved process. A pressure die casting equipment is often equipped with a vacuum mechanism to deal with the gas pores trapped inside a mold.
That’s why it is also known as vacuum-assisted high-pressure die casting too. It significantly minimizes casting defects involved during die casting and helps to reduce wastage.
Squeeze Die Casting
It is a simpler form of the high-pressure die casting process. It is often a cheaper alternative for making certain types of parts. It works by pouring a preheated die with molten aluminum and pressing it with another die to form the casting.
Squeeze die casting’s capabilities are rather limited. The casting cycle is usually slower than other methods.
If you want to know more about die casting, you can also visit the website of NADCA ( North American Die Casting Association ).
What are Your Material Options for Aluminum Die Casting?
The aluminum alloy used for casting is different from those used in machining or forging. Casting requires the materials to have good fluidity. Aluminum is alloyed with some elements to increase its fluidity properties and make it more suitable for die casting.
Some of the aluminum alloys we recommend and use ourselves are,
- AlSi9Cu3 etc.
There are many other aluminum alloys available in the market too. You are welcome if you want us to use a particular alloy. We shall assess its suitability and arrange it for you if possible.
Looking to learn more about the aluminum die casting alloys and properties.
How Can Your Company Reduce the Aluminum Die Casting Cost?
A significant cost associated with aluminum die casting is due to the high tooling cost. Because die casting tooling is done using CNC Machines. And CNC machining can be pretty expensive based on the complexity of the parts you are producing.
Certain design tips can greatly reduce machining time and cost for you. Some of them are discussed below.
Maintain Adequate Draft Angle
Draft Angle is the vertical inclination of outer walls along the parting line. It is provided to allow easier removal of casting from the die. You can see a similar feature in cupcakes as well. They have a larger diameter at the top and a smaller diameter on the bottom.
Keep Undercuts Minimum
Avoid undercuts in your custom designed casting parts. If your product must include some undercuts, at least keep them aligned with the parting line. If undercuts are not appropriately placed, they complicate the casting process. Thus make it too expensive or impossible to cast.
Avoid Sharp Edges
Any sharp edges in your dies make both machining and casting difficult. Machining sharp edges require CNC machines with high accuracy, which are also more expensive. And sharp edges in dies makes it difficult to remove a casting and often damage the edges.
Avoid Intricate Features
The tooling cost will drastically increase with the rise in complexity. Keep your design simple, and avoid unnecessary details. Try not to keep any deep pockets and avoid thick walls in your designs. Maintaining a uniform wall thickness is advised as well.
Following these guidelines can significantly simplify the machining process and reduce the production cost of aluminum die casting.
Why Aluminum Die Casting Process is Most Popular in China?
Compared with aluminum die casting manufacturer in India, China has the largest share in the production industry. And Chinese manufacturers are racing against each other to develop cost-effective and efficient production methods. High pressure die casting is by far the most widely used die casting technology in China.
As we stepped into the modern era, our demand for high-quality products kept on increasing. In order to meet the growing demand of end-users and manufacturers need a faster and economical production approach.
With so many die casting companies available right now, assurance of the highest quality is of prime importance. High-pressure die casting is the most viable process for the mass production of aluminum parts. Some manufacturers are also adopting vacuum-assisted machines for better quality.
Aluminum Die Casting Manufacturer
- What is the Influence of Aluminum Die Casting Companies in the Industry?
- What Services are Offered by an Aluminum Die Casting Manufacturer?
- What are the Qualities of a Good Aluminum Die Casting Supplier?
- How to Find a Reliable Aluminum Die Casting Manufacturer in China?
- How to Maintain Good Cooperation with Aluminum Die Casting Manufacturer in China?
What is the Influence of Aluminum Die Casting Companies in the Industry?
Until the last century, steel and iron parts had dominated the metalworking industry. They were the most reliable option for high-quality parts with good strength. Back then, aluminum used to be a luxury metal due to a lack of proper technology for refining aluminum.
When aluminum was first discovered, its price was very high and even exceeded that of gold. In 1889, the first industrial process for aluminum production was invented. After that, aluminum prices rapidly dropped and became available worldwide.
The application of aluminum continued to grow in numerous products that relied on other metals before. The global aluminum production increased multi-folds by the mid-20th century. Aluminum became a common metal in everyday goods.
After the Second World War, another industrial revolution took place, which completely restructured the manufacturing industry. With the industrialization of advanced machining and casting tools, manufacturers began mass-production of aluminum parts.
After that, we were introduced to newer and better technology every decade. And modern computer numerical controlled machined further simplified every manufacturing methods. Manufacturers started to look for cheaper and efficient ways to produce parts.
With the advancement of technology, previous casting equipment was optimized for better production capacity with less cost. Now, aluminum die casting became one of the most cost-effective approaches for metal parts production.
New aluminum die casting suppliers are emerging every year. And the global market share of aluminum die casting is rapidly increasing worldwide. The industry is estimated to grow even more in the upcoming years.
What Services are Offered by an Aluminum Die Casting Manufacturer?
Aluminum die casting vendors in China usually provide multiple types of services associated with your die casting project. The number of services a supplier can provide simply demonstrates the ability to handle your project better.
Die casting suppliers usually offer the following type of services to their customers.
- Help Mold Design and analysis
- Provide Design for Manufacturing
- Die tooling with CNC machining
- Die casting
- Surface finishing for completed parts
These are commonly desired services that every customer wants from their supplier. Make sure the company you are partnering with has these services.
What are the Qualities of a Good Aluminum Die Casting Supplier?
It would be best if you verified some basic qualifications of the die casting factory before you hand over your important project to them. Here are some important tips for you.
- Die casting vendors should have experienced engineers to help you optimize your design to suit their production facility.
- All necessary die casting equipment should be available in-house. There is equipment with varying accuracy rating. Make sure they have the right set of tools to meet your requirements.
- The foundries should have proper safety measures and hazard-free work environment. It provides added security for your projects from any unprecedented incidents.
- The latest technology machining tools should be available for handling complex tasks. Your die casting molds are one of the main determinants of the quality of your parts.
- Sometimes you may face unusual demand for your products. Your supplier should be well equipped to tackle your demands.
- Proper QA test equipment and expertise should be available. Often quality control can play a more critical role than the casting itself.
- Suppliers with an in-house surface treatment facility are preferable. It can save you both time and money wasted behind looking for a separate surface finishing company.
How to Find a Reliable Aluminum Die Casting Manufacturer in China?
China is dominating the manufacturing industry right now. Due to the abundant land resources, raw material availability, and substantial human resources; Production cost in China is much more reasonable than any other country in the world.
So, companies from abroad are depending on Chinese aluminum die casting manufacturers for the production of their products. But there is too many aluminum die casting manufacturers in China, and it is a tough decision to find the right supplier for your project.
So, when you are looking for an Aluminum die casting supplier in China keep these following facts in mind.
- Look up the online business directories for a supplier
- Check out recommendations from your business contacts
- International trade shows are a great opportunity as well. Review the recent trade shows to find a vendor that interests you
- Check out the company’s die casting equipment and quality management system
- Try to find any customer feedback about the company
- Make sure the company complies with the international standards
How to Maintain Good Cooperation with Aluminum Die Casting Manufacturer in China?
The Client-Supplier relationship is a crucial parameter for any business. There must be a proper understanding between them in order to get mutual benefits. Here are some tips that will help you maintain a good relationship with your supplier.
- Explain your project in detail. Communication is the key. Keep your terms and requirements clear. It can minimize the chances of conflict with the trade.
- If you are from a different country, respect the cultural differences of each other.
- The employees may not be familiar to your language or have a different tone of speaking. Keep consideration for such occurrences.
- Meeting with your supplier will leave a positive vibe, and you will hopefully notice the differences later on.
Keep these tips in mind for a successful partnership with your vendor.
The Capability of Sunrise Metal
- What are Your Aluminum Die Casting Capabilities?
- Can You Design My Parts and Execute Mold Flow Analysis for Aluminum Die Casting production?
- Do You have Machining Facilities for Aluminum Die Casting Tooling?
- Can You Provide Surface Finishing for My Aluminum Die Cast Parts?
- Can You Provide PPAP and Patent Our Work?
- Can You Utilize Aluminum Die Casting Resources from Other Manufacturers?
What are Your Aluminum Die Casting Capabilities?
We are a leading aluminum die casting company in China. Our vast capabilities have enabled us to handle critical projects and provide on-time delivery. Here are some of our services and facilities that might be helpful for you.
Advanced Die Casting Equipment
Our die casting shop is fully equipped with the latest technology aluminum die casting equipment. These are all cold chamber die casting equipment with different tonnage to match your precision requirement and size of the casting.
Some of the equipment is optimized to carry out a critical die casting project. We also have vacuum-assisted systems for reducing casting defects and offer higher quality parts.
High Precision QA Test Devices
We have advanced QA test devices that can measure the accuracy of your parts to a great extent. We can also detect any defects in your parts. We thoroughly check every part and make sure you get the absolute best quality from us.
Vast Choice of Alloys
We allow popular aluminum alloys, e.g., ADC12, A380, AlSi9Cu AlSi10, etc. for production. You can also request us to use other aluminum alloys of your choice as well. We try our best to meet our client’s demands to the fullest.
Can You Design My Parts and Execute Mold Flow Analysis for Aluminum Die Casting production?
Yes, we have experienced designers and the necessary hardware required to design parts for you. We are also capable of creating effective simulations for a mold flow analysis in advance.
So, our talented engineers can design your parts with a high degree of accuracy and optimize them for easier production. It helps to cut down aluminum die casting cost as well. Our advanced mold flow simulations can prevent inefficient design approaches and defects.
Do You have Machining Facilities for Aluminum Die Casting Tooling?
Yes, we have CNC machining facilities! We pride in our first-class CNC machining capabilities that allow us to complete delicate die casting tooling projects. In fact, we have a dedicated tooling shop located in the Nantong prefecture of China.
Our CNC Machining capabilities include,
Machine centers are convenient for their ability to carry out machining tasks with minimum human interactions. They are equipped with a tool magazine that can automatically change tools and perform multiple CNC machining processes.
Multi-Axis CNC Machines
We have the latest 5-Axis and 7-Axis CNC machines that are capable of carrying out intricate machining tasks that are often difficult or impossible with normal CNC Machines. So, we can confidently accept any tooling project.
Assurance for Accuracy
We have sophisticated instruments for measuring the precision of our work. Our Coordinate Measuring Machine can accurately calculate the geometric coordinates of the die casting mold and finished parts. So, you can rest assured about the accuracy of your parts.
Can You Provide Surface Finishing for My Aluminum Die Cast Parts?
Yes, we have our in-house surface finishing facility. We want to ensure an economical surface coating solution for you. So we provide most of the basic surface finishes such as cleaning, shot blasting, etc. within our factories.
We are also partnered with expert surface finishing agencies to avail more options for you. When you need more advanced surface finishes, we can arrange it for you. So, you can get powder coating, chrome plating, anodizing, nickel plating, etc. services from us too.
Can You Provide PPAP and Patent Our Work?
The Production Part Approval Process (PPAP) is an essential part of the automotive and aerospace industry’s product development process. We shall help you through the entire approval process. So, you don’t have to worry about it.
We also patent any unique manufacturing techniques used for a client’s project. We provide customized solutions to our clients that suit the requirements of their project. We are always looking forward to finding innovative production approaches.
Can You Utilize Aluminum Die Casting Resources from Other Manufacturers?
We shall try our best to meet our client’s satisfaction. We will thoroughly assess any previous resources (e.g., die casting molds) you have from your last project. We will utilize the dies in our project if possible.
But do not worry if the resources you have are not in perfect shape and needs repairs. We provide die repair and maintenance services to utilize your old dies and preserve it for long term usage.
Quality Control of Sunrise Metal
- Are You a Certified Aluminum Die Casting Vendor?
- How does Sunrise Metal control the quality of production processes?
- what kind of Quality Control instruments used at Sunrise Metal?
- How does Sunrise control the part’s traceability?
- Is Sunrise Metal a Continually Improved Company?
Are You a Certified Aluminum Die Casting Vendor?
Yes, Sunrise was issued the ISO 9001 certification in 2015 and the IATF16949 certification in 2016. These certifications signify our superior quality management systems. The ISO 9001 evaluates the quality management system of our company as a whole.
ISO 9001 certificate is given when a company fulfills the following criteria,
- All regulatory and statutory requirements stated in the manual are met
- Should have efforts towards improving the production efficiency and quality
- The quality management system should be strong and efficient
- Should have satisfactory customer service to develop business relationships
- Take proper measures for creating quality awareness among the employees
The IATF16949 certification is an international standard for quality management for the production of automotive parts. The following conditions must be satisfied to obtain this certification.
- Regulate the company services and product quality for improving customer satisfaction
- Should have continual development in existing production and quality control measures
- Proper technical expertise and QA test equipment to avoid any product defects
- Adopt processes with less waste generation and resource consumption
- Efforts towards enriching existing production facilities and workforce
How Does Sunrise Metal Control the Quality of Production Processes?
Sunrise Metal has a superior quality management system certified by ISO 9001 and IATF 16949. All our quality control processes abide by these international standards. We pride in our quality management and can guarantee maximum quality for the parts we produce.
We maintain optimum quality control in all stages of production. The complete quality control process of Sunrise Metal is explained below.
Inspection of Raw Material
The incoming raw material properties are thoroughly tested with the help of a spectrometer. It helps us verify the raw material specifications by identifying the parameters such as,
- Grade of the Alloy
- Chemical Composition
- Purity, etc.
No matter how good quality control measures are in motion in the later stages of production, optimum structural integrity and performance can’t be achieved without good raw material.
FAI and LAI for Die Casting
Many suppliers will only conduct an FAI for die casting. But Sunrise Metal runs both First Article Inspection (FAI) and Last Article Inspection (LAI) during the manufacturing process. The FAI allows us to verify whether or not the manufactured part can meet your requirement.
But sometimes the die casting setup may deter from the initial condition. So, we carry out LAI and do random sampling of parts every two hours to ensure that the quality remains the same for the entire batch of parts.
Optimization and Inspection of the Machining Process
Proper assessment of the parts is needed to ensure its manufacturability. Certain geometric features in a design can make it impossible or very difficult to machine. We provide effective design for manufacturing to avoid such issues.
We simulate the whole machining process beforehand to minimize the chances of errors during production. We also inspect the completed parts using CMM to measure the dimensions.
Surface Treatment Quality Inspection
The surface finishing provided to the parts is inspected using multiple inspection equipment. The color of the parts is assessed with a color meter. Thickness testing machines are used to verify the uniformity of coating thickness. We also have salt spray testers to assess the durability of the surface finishing.
The finished parts are given a final check before they leave our premises. Performance and reliability assessment of the parts is carried out to ensure that the parts meet the specifications required by the customer.
Finally, the parts are given identification marks for ease of traceability. So, we can deal with product quality issues if any arises during usage. It allows us to deal with defective products faster and creates scope to enhance and predict quality for future production.
What Kind of Quality Control Instruments are Used at Sunrise Metal?
Sunrise Metal has dedicated instruments to ensure the optimum quality of any machined or cast parts along with the surface finishing. Some of the fundamental types of instruments available at Sunrise Metal are as follows.
Dimension Measuring Instruments
Coordinate Measuring Machine (CMM): CMM’s can accurately measure any geometric features by sensing discrete points on its surface with a probe. We have the leading-edge Zeiss Contura G2 CMM from the widely renowned Carl Zeiss brand at your service.
It allows us to take high-speed measurements with excellent accuracy. It also has an automatic scanning function. Its flexibility promotes better quality control of complex casting parts. Here’s a video of our employee operating the Zeiss CMM.
Caliper: We have calipers for taking measurements of standard tolerances. This allows us to take quick measurements that involve less time and labor.
Integrity Assessment Instruments
X-ray Detector: We can identify any internal defects present in the casting parts with the X-ray detector. It allows us to deal with critical issues like cracks and porosity. So, we can maintain optimum quality control and ensure maximum structural integrity.
Spectrometer: We can measure the spectral elements to verify the chemical composition of raw material and casting parts. This we can confirm the structural integrity of parts.
Hardness Testing Machine: It is a very useful instrument for measuring the mechanical strength of parts. So, we can ensure that our parts meet your required specifications.
Surface Finishing Testing Devices
Salt Spray Testing Equipment: We use this instrument for getting a relative measure of the corrosion resistance of surface finishes. It allows us to provide an estimation of the durability.
Thickness Testing Machine: We use a non-evasive testing device to check the thickness of the surface finishing. And we ensure that there are no irregularities in the parts.
There are many other quality control instruments available here as well such as,
- Color Meter
- Leakage Test Equipment
- Cleanliness Test Equipment
- Projector, etc.
These help us assess the different physical and mechanical properties of the casting parts and the quality of the surface finishing.
How Does Sunrise Control the Part’s Traceability?
Traceability is a prerequisite for the quality management system of any company. It is a company’s ability to uniquely identify and track all processes from raw material collection to production, supply, sales, and consumption of their manufactured goods.
It allows the manufacturer to trace a part back to its origin from any stage of the production or distribution process. So, the company can acknowledge valid claims to recall their products in case the consumer encounters a defective product.
This helps build trust for a company as the consumer is aware of the source and quality control measures involved in manufacturing. It also increases the transparency and credibility of warranty terms of a part.
So, Sunrise metal values part’s traceability and treats it as an inherent element of the quality management system. We ensure proper traceability of parts through the following procedures.
Assign Batch Control Card
We have a Batch Control Card for every batch of production. All traceability parameters of that particular batch are recorded in the card. It allows us to keep track of important things such as,
- Time of production
- Shift leader in charge
- Operators working on that batch
- Production quantity, etc.
Lettering and Labeling of Individual Parts
Being able to uniquely identify each part is also important. So, we provide the parts with a unique identification number. For tracing die casting parts, we usually include lettering in the mold. We ensure traceability through labeling, printing, and laser etching as well.
The following details are usually included for traceability,
- An ID no. for each part
- Work details
- Part dimension
- Inspection results, etc.
Is Sunrise Metal a Continually Improved Company?
Sunrise Metal has not achieved the recognition of a qualified aluminum die casting manufacturer overnight. We have been associated with the die casting business for more than ten years now. Through years of hard work and dedication of our employees, we have managed to make it this far.
Enhancing Technical Capabilities
We have a strong core competence backed by our superior engineering support and technological capability. Our extensive experience in this field allows us to provide the best manufacturing solution according to your economic constraints.
Our technological advancement also enabled us to substantially increase our production capacity. Our innovative production techniques can offer a higher yield rate with excellent repeatability.
Optimizing Production Practices
We are relentlessly optimizing our manufacturing techniques to boost our workflow and gain more efficiency. We are gradually shifting towards automation to reduce manual labor and speed up the overall production process. This will also reduce the chances of man-made errors and reduce waste.
Our rapid manufacturing processes are already efficient enough to offer you half the usual lead time. But, we are trying to go beyond by introducing innovative production techniques that can meet your demands.
Investing in Innovation
Sunrise Metal is continually investing to keep the crew and services updated with the latest technology. We use advanced manufacturing and inspection equipment to ensure maximum quality. We are also training our employees to advance their knowledge and experience.
Our R&D department is dedicated to introducing unique ideas to boost your production. We are committed to providing our customers with long term benefits through continuous innovation.
We aim to provide you a more fulfilling experience as you keep working with us. We are always improving, and we will always have something better to offer.
Partner With Sunrise Metal
- Why Should You Choose Sunrise Metal as Your Aluminum Die Casting Partner?
- Where is Sunrise Metal’s Aluminum Die Casting Foundry Located in China?
- What are the Production Capacity and Minimum Order Quantity of Your Company?
- Do You Provide Aluminum Die Casting Services for Companies Outside of China?
- How Does Sunrise Carry Out Aluminum Die Casting Operations?
- What Type of Companies have You Worked with Before?
- How Can I Request for Quote (RFQ) from Your Company?
Why Should You Choose Sunrise Metal as Your Aluminum Die Casting Partner?
Sunrise Metal is one of the rising aluminum die casting manufacturers in China. With our excellent customer service and quality of work, we have provided excellent service to our customers worldwide.
Here are some of the remarkable things about our company which should convince you why we are the right partner for your project.
Priority Customer Service
Customer satisfaction is our highest priority. We aim for maximum customer satisfaction and try our best to help you with your project. You shall guide you in every step of your production and give you the best possible solution for your project.
Sunrise Metal is not just a die casting factory. We have all sort of necessary production and quality control equipment required before and after casting. We have capabilities to help you from the beginning to completion of your project.
Two Die Casting Factories
Sunrise owns two die casting factories at Nantong and Kunshan. It should give you a good idea about the scope of our business. Our die casting facilities are enriched with the latest technology machines and are capable of handling complex jobs.
Sophisticated Quality Management System
We pride in our superior quality management system. Our strict quality control measures and corporate culture ensures the perfection of your work. We used advanced QA test equipment and employed a dedicated team for assuring the quality of your castings.
Wide Range of Equipment
We have a large collection of die casting equipment ranging from 280T to 800T. So we can carry out any small to medium volume operation with ease. We can maintain your required precision requirements as well.
Strong Command of English
It is a crucial trait for any Chinese aluminum die casting company. We have to deal with many foreign clients, so all of our employees are instructed to maintain communication in English. We focus on giving you a welcoming feeling.
You can find out more about our services in other guide articles and blog. You are welcome to check them out as well.
Where is Sunrise Metal’s Aluminum Die Casting Foundry Located in China?
Sunrise Metal factories are located in the Jiangsu province of China. We have a total of four foundries right now. Two of them are located in Nantong prefecture, and two of them are located in the Kunshan sub-prefecture.
Among these four, two of our foundries specifically carries out die casting operations. They are located in Nantong and Kunshan. Having two die casting facility at two cities help us operate easily and partner with more companies.
What are the Production Capacity and Minimum Order Quantity of Your Company?
We have enriched die casting facilities with modern equipment and experienced employees supervising the projects. Our properly executed supply chain management allows us to work efficiently and boost our production capacity.
We can produce up to 5000 aluminum parts on our current die casting facilities. We accept orders for any high-mix, low-volume projects as well. Unlike other big suppliers, we offer maximum dedication and customer support for all our customers.
So, startup companies and OEM/ODM can greatly benefit from our services.
Do You Provide Aluminum Die Casting Services for Companies Outside of China?
Yes, we provide our aluminum die casting services worldwide. We have extensive experience for many foreign companies outside of China.
Till now, our client list extends over five hundred and still counting. Most of our customers are from Europe, Asia, and North America. We are eager to extend our reach to more customers and provide our services to other regions too.
How Does Sunrise Carry Out Aluminum Die Casting Operations?
Sunrise focuses on aluminum die casting manufacturing. That’s why we use cold chamber equipment for die casting aluminum parts. It is a variant of the high-pressure die casting process. It is used for materials like aluminum that has a high melting temperature.
Our die casting procedure is explained below for a better understanding.
3d Modeling of Parts
We need a model of your parts before we can get started. Submit the 3d model of your parts to get a quote of your project. You can also ask us to help you with your design.
Mold Design and Flow Analysis
The next step is optimizing your Design for Manufacturing. Our engineers will design the die casting mold according to your parts design and run simulations. It helps to find out any possible defects associated with the design.
Once the design is final, we proceed with creating the die casting injection mold. The molds are made using high precision CNC machines. It will offer excellent dimensional stability and accuracy for your die-cast parts. When the tooling is complete, assemble the molds in a die casting machine.
An aluminum alloy of your choice will be selected based upon your requirements. We assess the quality of raw material and send it to a furnace for melting. We shall add proper additives if required, to improve the metal quality and get rid of impurities.
The molten aluminum alloy is carried into the die casting machine using a ladle. The melt is poured into a cylinder and shot inside the die cavity using a plunger. The high pressure exerted by the plunger will ensure that the melt reaches every recess of the cavity.
After injection, the fluid aluminum is left inside the mold to cool down and solidify. Once solid, the die is ejected, and casting is retrieved from the machine. Then the machine is sprayed with a water jet to prepare it for the next cycle.
The completed casting is trimmed down to remove sprue, runners, gates, flash, etc. It will also separate multiple aluminum parts that were cast together. Then you can choose to apply your desired type of surface finish for your parts.
What Type of Companies have You Worked with Before?
We have over 10 years of experience in the metalworking industry. Within the course of these years, we have worked for many companies worldwide. They were from different industries, and the parts were manufactured considering their possible applications.
Till now, the total number of clients served by us is more than 500. They were different regions of the world. We have successfully ensured high-quality parts and on-time delivery for each of our clients.
We have rich experience in die casting automotive parts and medical devices. We have also successfully supplied parts maintaining proper protection standards for the marine environment. We produced tons of parts for telecommunication devices and general consumer goods as well.
How Can I Request for Quote (RFQ) from Your Company?
We need some basic details about your project to give you a probable estimate. You can either contact us through our online chat or mail us the required information. Some important information you should mention in your RFQ is as follows.
- Submit a 3d CAD file of your model. Attach any 2d model as well if available, they help us better assess the design. You can also contact us if you need help completing your model.
- Let us know your quality, precision, and strength requirements. If you have a preference for a particular aluminum alloy, mention that as well.
- Specify your order quantity and preferable deadline.
Write up the information in detail for an accurate quote. We shall get back to you as soon as possible.