Die Casting Tooling Capacity - In-House Die Design

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	28-112 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	-	2-4 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	3-5 weeks
Production single cavity, simple	H13	5-8 weeks
Production single cavity, medium	H13	6-8 weeks
Production with 1-2 slides	H13	7- weeks
2- cavity production	H13	7-10 weeks
Expedited (single cavity simple)	P20/H13	2-4 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: casting@kastdiecast.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China

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