Die Casting Sample Approval Process | FAI to Production

The sample approval stage decides whether a die casting project can move safely into production. A good approval process checks more than appearance; it confirms dimensions, machining, surface finish, assembly fit, pressure performance, packaging, and documentation.

KastMfg uses a structured sample approval process for new tooling, transferred tooling, and major engineering changes.

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Sample Approval Stages

Stage	Purpose	Output
Tool trial	Confirm filling, ejection, flash, porosity risk, and basic part quality	Trial report and sample parts
Process adjustment	Stabilize injection speed, pressure, die temperature, and cycle time	Locked trial parameters
First article inspection	Measure drawing dimensions and key GD&T features	FAI report
Machining validation	Confirm datum scheme, bores, threads, sealing faces, and flatness	Machining inspection report
Surface finish approval	Confirm coating, texture, color, and corrosion requirements	Approved finish sample
Buyer testing	Fit, function, assembly, leak, thermal, or durability checks	Buyer approval or correction list
Production release	Finalize process controls and inspection plan	Approved production launch

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What KastMfg Checks Before Sending Samples

Before samples are released, KastMfg verifies:

• Visual casting quality
• Flash and parting line condition
• Critical dimensions from the drawing
• CNC-machined features
• Thread quality using go/no-go gauges
• Sealing face flatness where required
• Coating or finishing appearance
• Packaging protection for shipment

For automotive programs, PPAP documentation can be prepared according to the buyer's required level.

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Buyer Responsibilities

The buyer should review samples against the actual use condition, not only the drawing. Typical buyer checks include:

• Assembly fit with mating parts
• Functional testing under load, pressure, or temperature
• Coating acceptance under real visual standards
• Packaging and labeling review
• Confirmation of any open deviations
• Written approval before production launch

Fast written feedback helps prevent schedule drift after samples arrive.

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When Samples Fail Approval

Sample issues are normal in die casting launches. The important question is whether the issue requires:

• Process adjustment only
• CNC program or fixture change
• Minor tool correction
• Major tool steel change
• Drawing or tolerance revision

KastMfg separates each issue by root cause and recommends the lowest-risk correction path before the next sample run.

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Related Resources

• Die casting tooling lead time
• Die casting sample lead time
• PPAP die casting explained
• Quality control

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Sample approval inquiry: yaoqingpu1983@gmail.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China