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China OEM Zinc Alloy Die Cast Auto Spare Parts Factory | Custom CNC Machining Suppliers
Manufacturing Process
Step 01
ZINC Die Casting
Equipment & Materials:
138T zinc die casting machine; ZA 3# material.
Process Characteristics:
- The furnace temperature is 420°±20°, and the material handle is 14±1 mm.
- Secondary materials cannot be used.
- Material composition must be tested to ensure it is suitable for production.
- First piece confirmation is required after die-casting.
Precautions
- Confirm surface filling quality: no bulging, no cold isolation, and no shortage of materials in the column.
- Avoid mold sticking, mold drawing, or poor ejector pin protrusion.
- Ejector pin should be concave 0-0.2mm; for machined surfaces, it should be convex 0-0.2mm.
Step 02
Remove Water Gap
Tools:
Stick / saw machine
Things to Note
- Ensure surface is not crushed and has no lack of material.
- Maintain strict dimension control.
Step 03
IPQC Inspection
Testing Instruments:
Three CMM, appearance visual evaluation, projection, Caliper.
Precautions
Use measuring tools correctly and check dimensions according to drawings.
Step 04
Deburring
Process Details:
Inverted R angle at sharp angle positions, deburring, non-machining surface top needle draping, grinding and connecting shape.
Equipment:
File, Wind mill, 120# sandpaper.
Note
- No residual segment difference.
- Don't grind over cut.
- Hold the product lightly to prevent pressure injury or deformation.
Step 05
IPQC Inspection
Process Details:
Visual inspection of appearance.
Equipment:
Knife-edge ruler, shaping fixture, Rubber hammers, rubber pads.
Note
Visual inspection of appearance, according to SIP.
Step 06
CNC Machining & Full Inspection
Process Details:
Drilling 1x ϕ2.0 through hole (through 2 sides), drilling 3x ϕ3.0 through hole on the side.
Equipment:
Automatic drilling and tapping machine table, ϕ2.0 drills, CNC Drilling.
Note
- Do not over-cut or miss processing.
- Be careful not to scratch or burr the surface.
- Through-hole tolerance within +/-0.1mm.
Step 07
IPQC Inspection
Process Details:
Needle Gauge Inspection.
Note
Through-hole needs to pass the needle gauge, according to SOP.
Step 08
Grinding
Process Details:
Sanding around and on the sides of the product.
Equipment:
Wind grinder, 120# sandpaper.
Note
No processing should be missed, no sharp corners or burrs should be removed, and the R corners should be connected smoothly.
Step 09
IPQC Inspection
Process Details:
Visual inspection of appearance.
Status
Standard visual quality control check.
Step 10
Oil-Spraying
Material:
Sherwin-Williams paint.
Note
- The surface must be smooth, with no color variations or dirt.
- The surface cannot have orange peel or loose particles.
- The surface should not be scratched or stripped of paint.
- Color must match the sample, remaining uniform and consistent.
Step 11
IPQC Inspection
Process Details:
Post-coating verification.
Note
- Surface quality confirmation after oil spraying.
- Holes require needle gauge sampling inspection.
Step 12
Full Inspection & Packaging
Equipment:
Carton, knife card, clapboard, bubble bag.
Note
- Appearance inspection according to sample; ensure surface is free of dirt, scratches, or bad dents.
- Each product must be put into a bubble bag before being placed into the packing box.
Step 13
FQC Inspection
Test Tools:
Calipers, projectors, pin gauges, tooth gauges, visual and packaging inspection.
Note
Verify whether the measuring tools are within their calibration period.
Step 14
Transportation
Process Details:
Logistics preparation.
Note
- Confirm that the quantity matches the purchase order.
- Label and stamp the outer box correctly.
- Send reports on shipments.
Step 15
OQC Shipping Inspection
Testing Instruments:
Calipers, projectors, pin gauges, tooth gauges, outer packaging inspection, etc.
Note
Ensure the measuring device is within its calibration window and meets both customer and SIP requirements.
Frequently Asked Questions
Q1:
What raw materials and machinery are used during the initial die casting phase?
We utilize a 138T zinc die casting machine and ZA 3# material. The furnace temperature is strictly maintained at 420°±20°, and secondary materials are strictly prohibited to ensure maximum structural integrity.
Q2:
How is quality controlled during the IPQC inspection phases?
Quality is monitored continuously using specialized tools, including three-coordinate measuring machines (CMM), projection systems, calipers, and needle gauges. Inspections are conducted strictly in accordance with SIP and SOP guidelines.
Q3:
What tolerances are maintained during CNC machining?
During the CNC drilling process (which includes drilling 1x ϕ2.0 through holes and 3x ϕ3.0 side through holes), we maintain a strict through-hole tolerance within +/-0.1mm while carefully checking to avoid surface scratches or burrs.
Q4:
What paint and surface requirements apply to the oil-spraying process?
We use premium Sherwin-Williams paint. The coated surface must be completely smooth, match the approved reference sample, and show zero signs of orange peel, particles, scratches, or paint stripping.
Q5:
How are finished parts packaged and prepped for safe shipping?
Following a 100% visual inspection, each individual product is placed inside a protective bubble bag. The parts are then organized inside robust cartons utilizing knife cards and dividers to prevent surface contact and damage during transit.
Q6:
How does the factory ensure the accuracy of its measuring instruments?
During FQC and final OQC inspections, we verify that all test instruments (such as calipers, projectors, pin gauges, and tooth gauges) are within their active calibration windows to guarantee precise measurement data.