ALUYONIX Precision Die Casting
PROVEN SERIAL PRODUCTION EXPERTISE

Products & Serial Case Studies

Explore our portfolio of engineered metal castings. Each case study documents the design challenge, metallurgical intervention, and measurable outcome achieved for our OEM partners.

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HPDCAutomotive & EVWeight: 7.85 kg

EV Traction Motor Stator Housing

Alloy Material:Aluminium ADC12 / A380
Annual Volume:180,000 units
Critical Tolerance Achieved:±0.02 mm bearing concentricity
The OEM Challenge:

Customer needed a complex dual-layer spiral water-cooling jacket with zero helium leak allowance (>1.5 bar) and tight cylindrical runout for direct stator shrink-fitting.

ALUYONIX DFM & Tooling Solution:

Utilized MAGMASOFT flow and thermal simulation to redesign internal chill vents and gating runner. Implemented 1,800T high-vacuum HPDC cell with automated CNC 5-axis finish milling and 100% differential pressure leak testing.

Outcome: Eliminated micro-porosity reject rates from 8.4% to < 0.3%. Delivered 100% helium pressure-tight parts with Cpk > 1.67.
Tooling Cavitation: Multi-Cavity MoldQuote Similar Part
HPDCTelecomWeight: 11.20 kg

5G Massive MIMO Active Antenna Enclosure

Alloy Material:Aluminium ADC12 (High Purity)
Annual Volume:120,000 units
Critical Tolerance Achieved:±0.04 mm fin pitch and flatness < 0.25 mm
The OEM Challenge:

Required 140+ ultra-tall, thin cooling fins (1.8 mm base tapering to 1.1 mm over 85 mm height) across a 600 × 400 mm footprint without cold-flow knit lines or thermal warping.

ALUYONIX DFM & Tooling Solution:

Designed multi-zone conformal oil heating channels inside the H13 tool steel die. Deployed 2,500T HPDC cell with multi-point intensification curve and robotic vacuum evacuation.

Outcome: Achieved flawless fin fill without soldering. Integrated automated shot blasting and RoHS-compliant passivation for 1000-hr salt-spray corrosion protection.
Tooling Cavitation: Multi-Cavity MoldQuote Similar Part
LPDCAutomotive & EVWeight: 3.40 kg (Replaced 7.1 kg ductile iron)

Lightweight Suspension Steering Knuckle

Alloy Material:Aluminium A356-T6
Annual Volume:240,000 units
Critical Tolerance Achieved:±0.03 mm on ball-joint bores
The OEM Challenge:

Tier-1 OEM needed a 50% mass reduction over cast iron while maintaining strict crash impact elongation (>7%) and 10^7 cycle fatigue endurance.

ALUYONIX DFM & Tooling Solution:

Engineered in Low Pressure Die Casting with bottom-up laminar filling to eliminate oxide inclusion. Applied proprietary T6 solutionizing and artificial aging heat treatment.

Outcome: 52% weight savings achieved with 9.2% elongation at break. 100% digital real-time X-ray inspection verified zero ASTM Class 2 porosity.
Tooling Cavitation: Multi-Cavity MoldQuote Similar Part
Gravity Die CastingElectricalWeight: 9.60 kg

Explosion-Proof Switchgear Terminal Housing

Alloy Material:Aluminium LM25 / A356
Annual Volume:45,000 units
Critical Tolerance Achieved:±0.05 mm on O-ring groove depth
The OEM Challenge:

Heavy-walled pressure-tight casting required to withstand internal arc-fault blast pressures up to 30 bar without rupture or flame path breach.

ALUYONIX DFM & Tooling Solution:

Permanent mould Gravity Die Casting with insulated ceramic coatings to govern directional freezing. Implemented internal resin vacuum impregnation to guarantee zero micro-porosity.

Outcome: Certified ATEX / IECEx compliant for hazardous chemical and mining environments. Delivered over 150,000 units with 0 field ruptures.
Tooling Cavitation: Multi-Cavity MoldQuote Similar Part
Zinc Die CastingIndustrialWeight: 0.38 kg

Micro Planetary Gearbox Actuator Case

Alloy Material:Zamak 5 (High-Strength Zinc)
Annual Volume:500,000 units
Critical Tolerance Achieved:±0.015 mm as-cast without finish machining
The OEM Challenge:

Miniature robotic arm joint required cast-in internal gear teeth and bearing seats without requiring secondary CNC machining to hit cost targets.

ALUYONIX DFM & Tooling Solution:

Utilized automated Hot Chamber Zinc die casting with 4-slide multi-core tooling at 350 shots per hour. Cast-in threads and splines held directly out of the die.

Outcome: Saved the client $1.40 per unit in eliminated CNC machining operations with 100% interchangeable repeatability.
Tooling Cavitation: Multi-Cavity MoldQuote Similar Part

Have a Challenging Component with Strict Porosity Limits?

Our engineering team specializes in resolving leak defects, reducing machining cycle times, and lightweighting heavy ductile iron parts.

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