Choosing the right partner to supply you with quality die casting isn’t always easy. As prices rise and budgets are squeezed, buyers are looking for durable products made from premium metals. So you need a reliable, cost-effective supplier.

That’s why many UK and European companies look to Chinese companies for die cast product moulds. At Maxview, we work with a China-based company, Connexions, to produce casting moulds for many of our products, such as parts for our caravan WiFi routers and caravan satellite systems.

Here, discover if choosing a Chinese casting foundry is the right decision for your business.

‍What is the die casting process?

Die casting is a metal casting process used to produce intricate metal parts for specific products. Under extremely high pressures, molten metal is pushed through a reusable mould (also known as a die) to shape these components. The metal solidifies as it cools, creating a durable, quality product that can be easily removed from the die.

Die casting is an excellent way to create complex yet consistent metal designs. Some foundries have problems with hollow or intricate designs, especially if they use unsuitable materials or low-quality casts. So it’s essential to find a casting supplier that can provide quality parts without breaking the bank.

Should you choose a casting foundry in China?

If you’re concerned about cost, choosing a casting foundry in China is often a good option. While you’ll pay more in shipping, other costs tend to be cheaper than in the UK and Europe. And while not all Chinese die casting foundries provide topmost quality, by doing your research to find the right supplier, you can:

• Take advantage of advanced technologies — Many Chinese companies invest in more efficient, effective systems to produce quality parts.
• Customise your tooling — Connexions will support you to design and create the appropriate die for your product.
• Get fast, reliable shipping — Suppliers understand the importance of a reliable supply chain, so they often have excellent export capabilities.
• See tooling prototypes quickly — Tooling prototype turnarounds are quick, so you can make changes as needed and get production underway when you need to.
• Get the best value — Chinese die casting suppliers offer top economies of scale. The more you order, the cheaper the cost-per-part.

How a Chinese foundry can help with die casting

Let’s take a look at how a Chinese die casting supplier like Connexions can support you with specific casting processes.

1. Casting mould design

The first step in the process is designing your casting mould. This is a complex step, as all your parts will ultimately be created using the finalised die design. So it’s important to work with an experienced die casting partner that understands the critical nature of a strong, accurate design.

To make sure your die will provide the exact cast you need, Connexions will check the following points in your design:

• Injection gate and overall layout of the die.
• The distance between cavity and insert edges.
• Distance between cavities.
• Distance between the insert edge and the mould base edge.
• Thickness of A/B plates and inserts.

2. Casting tools

Tooling can be expensive. Cast prices range from $1,200 to $120,000, depending on the cast size, complexity, and material. So when you’re making this investment, you need to have confidence in your casting supplier.

Generally, a single tool for die casting will last around 70,000 production cycles, but it depends on the tooling construction. Higher quality tooling may last longer, giving you a greater return on your investment.

Connexions produces dies up to 1.5m². This gives customers substantial scope to create casting moulds for almost any product. Learn more about the pros and cons of tooling in China.

3. Quality assurance

Chinese casting suppliers may have different quality assurance processes to UK-based firms. So it’s important to discuss your QA needs with your potential supplier in advance.

Connexions is committed to excellent international-standard QA. They use the following processes to make sure every casting mould is accurate, durable, and fit for purpose:

• Casting mould drawing design, review, and update.
• Design validation and verification.
• Strict internal quality control for all raw materials.
• Mould prototyping, trial, and inspection.
• Electrode checking using coordinate measuring machining (CMM) and electrical discharge machining (EDM).
• Full dimensions measurement report.
• Dimension adjustment trial before a second mould trial.

Materials used in Chinese die casting

Quality raw materials for die casting often cost less for Chinese casting companies, who typically buy in bulk to get the best possible prices.

Commonly used metals in Chinese die casting include:

• Aluminium
• Zinc
• Copper
• Magnesium

In many cases, these metals are alloyed for use in die casting. Speak to your supplier to find out which materials and/or alloys are available.

Are there any drawbacks to working with a Chinese casting foundry?

Working with a Chinese casting supplier can help you save on casting moulds while also receiving quality dies and parts.

However, there are a few potential drawbacks to working with a China-based firm:

• Different standards — Quality standards may be different in China and the UK, so be sure to check if your supplier can meet your requirements.
• Communication barriers — With highly specific and complex designs under discussion, it’s important to be able to communicate effectively with your supplier. Fortunately, many Chinese suppliers employ fluent English-speaking staff to minimise communication problems.
• Die cast ownership — It’s important to establish who owns the die and any other tooling in advance to avoid intellectual property complications.
• Logistical challenges — While export and shipping processes are often seamless, it’s important to establish expected lead times and costs upfront.
• Continuity planning challenges — You’ll need to get to know annual festivals in China and plan around these to ensure you have the supplies you need when you need them.

Choosing the right casting supplier in China

If you’re considering working with a casting foundry in China, you can select a reliable supplier by getting recommendations from other businesses based in your region. Thanks to their fast, reliable processes, affordable costs, and high-quality production, we recommend Connexions to any UK-based business seeking a China-based casting supplier. Minimum order quantities of one mould and 1,000 products will apply, with lead times of 30 to 35 days.

To learn more about requesting tooling from Connexions, contact [email protected].