Contents:

CNC machining

Prototyping

die casting

mold design

die casting mold

one-stop industrial manufacturing services

3D printing

injection molding

metal injection molding (MIM)

metal stamping

Process: CNC machining, die casting, late surface treatment

Material: AL6061 aluminum alloy for Prototyping, ADC12 cast aluminum for mass production
Quantity: 200 sets

About the customer
Client H has been our important partner for many years. Company H is a global company that designs and manufactures artistic lighting. It owns a world-renowned brand. In its business field, Company H has a leading position in the industry.

About that product
This product is a main accessory in stage lighting, as well as an important internal functional piece.

About the project

First make a prototyping to verify the structure and design of the product, and then proceed to mass production. When we received the customer's design drawings at that time, we felt it was difficult for casting to achieve the precision required by the customer, but if CNC machining was used completely, the cost would be too high and it would be difficult to mass-produce.

In the previous generation of products, sheet metal parts were first made by stamping dies, and more than 20 parts on the handle were produced separately and then assembled by riveting and spot welding. It is difficult to achieve the precision required by customers, and the repeatability is poor, the production cost is high, and the strength test sometimes fails.

Therefore, the guests cooperated with our R&D team in the new generation of products to update the product structure. Now we mold it once by die casting, and then CNC machining the high-precision parts, which greatly simplifies the production process, shortens the production cycle, and reduces production cost. While increasing the overall strength of the product, it can also meet the precision requirements of customers.

Prototyping production
Since a generation of products had been produced before, the customer provided us with detailed and improved 2D drawings for making prototyping. The prototyping is finished by CNC machining and the material used is AL6061 aluminum alloy. Mastars has the most advanced 3-axis and German HERMLE 5-axis CNC machining centers in the industry. CNC machining can ensure the dimensional tolerance of the product and meet the precision required by customers.
Five days later, we finished the prototyping.

A major overhaul of design

After the prototyping was delivered, the customer's design and functional requirements were verified, and the drawings were revised in preparation for mass production. However, if all mass production is processed by CNC, the production cost is too high. Therefore, after many studies and discussions, both sides decided to still adopt the casting production process of the previous generation product and adjust the material to ADC12 cast aluminum.

However, the more than 20 parts on the handle of the previous generation product had to be produced separately and then assembled by riveting and spot welding. This processing method has poor precision, poor repeatability and high production costs.

 

Mastars' design team and production department have conducted research and testing many times, hoping to break through the production limitations of the previous generation of products, and change the production process to one-time die casting. More than 20 parts on the product are formed at one time, and then all dimensional and location tolerance requirements are completed by precision CNC machining. After continuous efforts, we finally achieved the expected design idea. But this major reform has not been smooth sailing and encountered some major technical challenges.

Challenges and Solutions
If you want to die casting at one time, the design of the die casting mold is very different from the previous generation of products, but in the process of design and testing, we encountered technical difficulties.
1. At that time, when we received the 2D drawings of the customer's new generation of products, we found that the tolerance requirements of this product were very high, and the tolerance of the intermediate hole for bearing installation reached -0.008-0.033mm. Moreover, the material here is thick. If we use the ordinary scheme to feed the glue from the outside, there will be sand holes in the middle, which cannot meet the precision required by the customer. Through years of rich experience and professional knowledge, our designers have designed a 3-point fine nozzle scheme to inject glue in the mold design. Then through the mold flow analysis, it is found that this scheme is feasible and can achieve the desired effect.

 

 
2. There is a big risk in this product that there is too much empty material at both ends of the product, the length of the product is relatively long, and the opening is too large to easily cause the product to deform, which can not meet the customer's requirements of length tolerance ±0.5mm and assembly hole spacing tolerance ±0.1mm between the two supporting feet. Later, we designed an auxiliary runner at this position, fixed both sides of the supporting foot, and removed the auxiliary runner with CNC machining, which avoided deformation and controlled the precision within the tolerance range required by customers.

3. In the post-processing process, we also encountered difficulties, how can we ensure all the dimensional precision in machining? After repeated research and discussion by the design and production personnel, they finally came up with a clever approach: in the process of processing, the bearing hole with the highest requirements will be processed in place first, and then take this as the fixed center, and then machining other positions, so as to ensure the dimensional precision and positional precision of all positions.

Mold design and manufacture

After identifying the solution, in order to achieve the mass production of this product with high efficiency and good consistency, Mastars first began to design and manufacture the die casting mold.

Once the plan is determined, the design and production of the mold will come naturally. We completed the design, manufacturing, mold testing, and acceptance of the mold within 30 days.

Mass production process

In mass production, the aluminum blank is first melted into liquid aluminum water in a furnace, and then the product blank is pressed out on a die casting machine with a prepared mold, and then the slag bag around the product is washed away, and then sent to polishing to remove the burr of the product.

The part is then placed on a CNC machine for finishing to achieve the demanding dimensions and finer surfaces.

For the product surface with appearance requirements, the product will be subjected to post-processing, such as sandblasting, oxidation, powder spraying, etc. Since this product is an internal functional part, it does not have high requirements on the surface of the product, so it does not need to do fine surface treatment in the later stage.

Finally, professional dimensional inspection of the parts is carried out to ensure that the customer's production requirements are met.

The effect
During the development of this project, we encountered a lot of difficulties, which caused the project to stagnate or even fail. However, Mastars engineers bravely faced difficulties and faced them head on. It is our consistent style to find and solve problems in design and production. After more than 30 days and nights of hard work, the project team finally produced fully qualified products that met the delivery requirements.

 

One-stop solution

The company has an experienced design and production team, German HERMLE 5-axis CNC machining center, AGIE Electrical Discharge Machine, Sodick Electrical Discharge Machine, Okuma, FANUC and other precision mold processing equipment, Sumitomo, Sodick injection molding machine, as well as CMM fully automatic Measurement laboratory.

We maintain long-term and good cooperative relations with world-renowned enterprises in various industries, and we are fully capable of providing one-stop industrial manufacturing services for global enterprises.

1.Receive product needs of customers, conduct efficient professional communication, fully understand and deepen customer needs.

2. Verify your original design by making the prototyping of the product, and help you find some defects in the design during the prototyping production process, so as to make more adequate preparations for the feasibility of mass production in the future.

3. After the acceptance of the prototyping, design the mass production products, conduct 3D modeling, design the mold, and determine the feasibility of the design scheme through mold flow analysis.

4.  Make use of rich industry experience and advanced automation equipment to manufacture all kinds of high-precision molds.

5. Large-scale production and processing, comprehensive processing technology: CNC precision machining, 3D printing, injection molding, metal injection molding (MIM), die casting, metal stamping, etc. Meet all your machining requirements.

6. Comprehensive product post-surface treatment process: polishing, oil spraying, powder spraying, sandblasting, anodizing, electroplating, etc., to create more perfect surface effect and better surface performance for your products.

7. Our testing center has advanced comprehensive testing equipment, such as German GOM ATOS TRIPLE Sacn III Blue ray 3D scanner, Swedish Hexagon CMM, 2.5-dimensional automatic image measuring instrument, Hitachi handheld X-ray fluorescence spectrometer, Switzerland TESA Height meter, Japan Mitohiro Roughness Meter, etc. All this ensure that your products meet the design and functional requirements.

8. Perfect after-sales service, professional engineering technology and sales staff 7x24h to respond to your after-sales needs.

Customer voice

The customer is very satisfied with the product. Steven, the customer's project manager, said: “Mastars has been our partner for many years, we have been trusting and achieving each other over the years, they have a first-class R&D team, and world-class craftsmanship. Every time we made prototypings, they raised problems in design and possible problems in mass production in the future, so that we can improve in time, which saved us a lot of time and cost and avoided many mistakes. We maintained very good communication during the whole process. We are very happy and relieved to have such a partner.”

Mastars Industries CO., LTD
        www.mastars.com
Email: marketing@mastars.com
Tel: +86 755-88210689
Fax: +86 755-8821 0685
Add: Building 6,Blue Sky Industrial Park, Ditang Road, Shajing Town, Shenzhen City, Guangdong, China