In-House Tooling Capacity

KastMfg designs and fabricates all die casting tooling in our own 4,500 m² tool shop. We do not subcontract tooling. This determines tooling quality, lead time predictability, and our ability to modify dies on-site when trial results require adjustment.

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Tool Shop Equipment

Equipment	Qty	Capability
CNC machining centers (VMC)	8	Up to 1,200 x 800 x 600 mm, ±0.005 mm
CNC EDM (spark erosion)	3	Complex cavity and insert geometry
CNC wire EDM	2	Precision insert cutting, hardened steel
Deep hole drilling	2	Cooling channels to 1,500 mm depth
CNC turning	2	Up to Ø600 mm
Surface grinding	2	Parting face flatness to 0.005 mm
CMM (tool shop)	1	Component verification before assembly
CAD/CAM workstations	6	UG (Unigraphics), SolidWorks, Moldflow

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Tooling Steel Grades

Grade	Hardness	Lead Time	Application
H13 hardened	44-48 HRC	Standard	Production aluminum/magnesium dies
P20 pre-hardened	28-32 HRC	Faster, lower cost	Prototype dies, short-run zinc
H13 premium	46-50 HRC	+2 weeks	Long-run high-cycle programs
S7 shock-resistant	54-58 HRC	On request	Gate inserts, high-erosion areas
Beryllium copper inserts	-	2- weeks	Thermal-critical cooling zones

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Die Design Process

1. DFM review and parting line definition -48 hours
2. Mold flow simulation -gate position, fill pattern, air entrapment, weld lines, warpage -before any steel is cut
3. Die design review -3D assembly submitted to customer for approval before machining
4. Machining and assembly -cavity, core, slides, cooling, ejector system all measured on tool shop CMM before assembly
5. Trial and qualification -trial run + first-article dimensional check; modifications made on-site same day if required

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Tooling Lead Times (Firm Commitments)

Tool Type	Steel	Lead Time
Prototype single cavity, simple	P20	3- weeks
Production single cavity, simple	H13	5- weeks
Production single cavity, medium	H13	6- weeks
Production with 1- slides	H13	7- weeks
2- cavity production	H13	7-10 weeks
Expedited (single cavity simple)	P20/H13	2- weeks (premium)

These are firm commitments, not estimates. If a program requires tooling by a specific date, KastMfg confirms feasibility before order acceptance.

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Die Maintenance Program

Alloy	Inspection Interval	Major Maintenance Trigger
Zinc	Every 100,000 shots	400,000+ shots (gate insert check)
Aluminum	Every 30,000 shots	80,000 shots
Magnesium	Every 40,000 shots	100,000 shots

Maintenance records documented in the die file, available to customers. All tooling is customer-owned upon full payment.

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