Electric Control System Die Castings: Why can't electronic control systems do without precision die castings?

What is Electric Control System Die Castings?

Electric Control System Die Castings are high-precision metal parts designed and manufactured for various electronic control modules, drive systems, power supply housings and other application scenarios. This type of product mainly uses aluminum alloy and is formed in one step through high-pressure die-casting. It has many advantages such as high structural strength, high dimensional accuracy, and good heat dissipation performance. It is widely used in key systems such as new energy vehicle controllers, intelligent manufacturing equipment, power electronic modules, and communication equipment.

Core Principle

The core of Electric Control System Die Castings is High Pressure Die Casting (HPDC), which is an efficient and high-precision metal forming process that is particularly suitable for mass production of complex aluminum alloy parts.

The process mainly includes four key steps:

Metal smelting: Select high-purity aluminum alloy and heat it to liquid in a special furnace. To ensure fluidity and final performance, the smelting process will strictly control the temperature and impurity content.

High-pressure injection: The molten metal is injected into the precision steel mold at extremely high speed and high pressure through the die-casting machine. High-pressure injection ensures that the metal completely fills the complex cavity of the mold, including fine heat sink fins, pin holes, internal threads and other microstructures.

Rapid cooling: The mold has excellent thermal conductivity and can quickly cool the aluminum liquid to a solid state within seconds. This rapid solidification process can refine the grains and make the structure dense, thereby improving the mechanical properties and dimensional stability of the finished product.

Demolding and post-processing: The solidified aluminum parts are automatically ejected and demolded, followed by deburring, grinding, CNC finishing, surface treatment and other links to meet the use requirements of electronic control systems.

Why is die casting particularly suitable for electronic control systems?

Complex integrated structure: Traditional processing methods often require multiple parts to be assembled, while high-pressure die casting can form complex structures at one time, effectively reducing assembly links and improving product stability.

Lightweight demand: Aluminum alloy has a low density, only 1/3 of steel. Combined with thin-wall die-casting technology, it is conducive to overall product weight reduction, especially suitable for weight-sensitive fields such as new energy vehicle control units and avionics modules.

Good thermal conductivity: The electronic control module will continue to generate heat during operation. Aluminum alloy die-castings can quickly transfer heat to the heat dissipation structure or external housing, thereby protecting internal chips, capacitors, inductors and other components and improving system reliability.

High consistency, suitable for mass production: The mold forming process ensures the consistency between products, and the tolerance can be stably controlled within ±0.05mm, which greatly reduces the assembly error caused by dimensional deviation and is suitable for OEM/ODM factories.

Core features

High precision:Made of high-precision molds, the dimensional tolerance of die-castings can be controlled within ±0.05mm, which can meet the requirements of complex structural design, such as pin holes, heat dissipation fins, and reinforcement ribs. It is particularly critical for small and medium-sized, highly integrated components of electronic control systems.

Thermal and electrical conductivity:Aluminum alloy itself has excellent thermal conductivity (thermal conductivity of 150~200 W/m·K) and a certain electrical conductivity, which helps to quickly dissipate heat inside the control system and improve the stability and service life of the whole machine; at the same time, it can also provide a good electrical contact foundation in some connection parts.

Strength and durability:Die-cast aluminum parts usually have a tensile strength of more than 200MPa, which is enough to cope with harsh working environments such as vibration, thermal expansion and contraction, and current shock. They perform well in products such as industrial controllers, automotive control boxes, and motor drive units.

Why must electronic control systems use Die Castings?

Precision guarantee: micron-level structure is formed in one step to meet complex design requirements

As a highly integrated carrier, the core components of electronic control systems have extremely strict requirements on structural accuracy. Especially in key parts such as plug-in interfaces, screw holes, heat dissipation structures, and positioning grooves, even micron-level deviations may cause signal interruption, poor contact, assembly offset, or abnormal function of the entire machine. Traditional plastic injection molding or sheet metal stamping is difficult to meet complex geometric shapes while taking into account high precision and stability. High-pressure die-casting technology, with high-precision molds + high-speed high-pressure molding processes, can control the dimensional tolerance within ±0.05mm, which not only ensures structural accuracy, but also completes the integration of multiple functional areas in one molding.

Heat sink fins: can be directly molded in the mold in one step, eliminating CNC secondary processing

Traditional heat sinks often need to be processed by CNC milling or subsequent assembly to process complex fin structures, which not only increases costs, but also has the problem of poor consistency. Die castings can form a multi-level, multi-directional fine fin structure in the mold at one time, with stable precision control and high surface finish. This not only significantly reduces the manufacturing difficulty, but also improves the heat dissipation area and efficiency, which is particularly suitable for the heat dissipation housing design of high-power electronic modules and heat-sensitive components.

Terminal slot/guide structure: ensure accurate alignment of plug-in modules and improve assembly efficiency

For functional areas such as connector slots, buckle guides, and positioning supports, die casting technology can directly complete its micro-structure design during the molding process to ensure that the pins are accurately positioned, the connection is reliable, and there is no deflection or empty position. This is particularly critical for the rapid insertion of electronic components such as controllers and drivers under high-density wiring, which greatly improves the automated assembly efficiency and module replacement convenience of the production line.

Product consistency: suitable for mass production, each part is almost the same, which is convenient for automated production

One of the biggest advantages of die castings is their excellent repeatability. With the help of high-rigidity steel molds and high-speed injection systems, each part can almost maintain consistent structure and size during the die casting process. This high consistency not only ensures the standardization of subsequent assembly, but also greatly reduces the quality inspection scrap rate caused by individual differences, improves the overall production efficiency, and is very suitable for medium and large-volume, zero-tolerance automated manufacturing scenarios in electronic control systems.

Thermal management revolution: fast heat conduction, breaking the thermal bottleneck of high-power equipment

With the increasing power density of control systems in electric vehicles, industrial automation, new energy equipment and other fields, heat has become one of the biggest threats to system stability. High-frequency switches, power chips, and processor modules will generate a lot of heat in a very short time when they are in continuous operation. If the heat cannot be dissipated in time, not only will the performance decline, but it may also cause device damage or burning. Therefore, thermal management has become one of the core considerations in the design of electronic control systems.

Aluminum alloy die-castings have become an ideal material choice for integrated structure + thermal management functions due to their excellent thermal conductivity and the ability to achieve integrated molding of complex structures. They are especially suitable for structural carriers, housings and heat diffusion components of high-power electronic modules.

Directly conduct heat to the housing or heat sink to avoid local heat accumulation

The die-cast aluminum alloy structure itself is an efficient heat conduction medium. In the design, the heat source element can be directly attached to the aluminum shell through a thermal pad or thermal grease to quickly conduct heat to the entire shell surface, and then dissipate it through natural convection or air cooling system. Compared with the structure that requires additional mounting of heat sinks, this integrated design greatly reduces the thermal resistance path, effectively avoids the "heat island" problem caused by excessive local temperature rise, and improves the overall thermal balance.

Fins, vents, and heat channels can be formed in one piece, and the design is flexible

One of the biggest advantages of the die-casting process is its one-time molding ability for complex structures. Through precision mold design, multi-layer heat dissipation fins, ventilation channels, thermal columns and other thermal management structures can be integrated into the aluminum alloy shell without subsequent CNC processing or welding. Designers can freely layout according to the distribution of heating elements and the direction of airflow to maximize heat dissipation efficiency. This high integration also reduces the number of components and assembly difficulty, significantly improving the overall reliability and design freedom of the system.

Case reference: Electric vehicle ECU structure + heat dissipation integrated solution

Taking the ECU control module of an electric vehicle as an example, multiple high-power chips, sensors and communication modules need to be run stably for a long time inside, which has extremely high requirements for thermal management. In a typical design, the ECU circuit board is directly embedded in the die-cast aluminum housing, and the outside of the aluminum housing is connected to the battery liquid cooling plate to form a heat exchange path, realizing the continuous conduction of heat from the source → structural parts → cooling system, and building an efficient thermal management system of "structural parts as radiators". This method not only improves thermal efficiency, but also saves structural space, making the vehicle's electronic system more compact and more reliable.

Die castings or plastics/sheet metal: all-round advantages in thermal management

Compared with plastic housings, aluminum die castings have nearly 100 times the thermal conductivity and can export heat instantly, while plastics have no heat dissipation function at all and may even deform due to high temperatures. Compared with traditional sheet metal structures, die-cast aluminum not only has better thermal conductivity, but also can achieve higher structural integration and precision control. In addition, die castings are more stable in thermal stress distribution and are not easily deformed or cracked due to drastic temperature changes. This enables it to maintain reliability and stable performance in extreme temperature differences and high-load operating environments.

Lightweight demand: structural strength remains unchanged, weight is reduced by more than 30%

With the trend of increasingly high density and high complexity of electronic control systems, how to effectively control weight without sacrificing structural strength and durability has become a core issue of concern to manufacturers in the industrial and automotive fields. Aluminum alloy die-castings have become an ideal material for realizing system lightweight design due to their unique advantages of low density (about 2.7g/cm³) but good mechanical properties.

Especially in scenarios such as new energy vehicles, intelligent equipment, and industrial automation, lightweighting not only means portability and beauty, but is also directly related to energy consumption management, endurance, system response speed, and transportation costs. Therefore, it is becoming a rigid requirement for mainstream design.

Lightweight trend of new energy vehicles - directly affecting endurance and vehicle energy efficiency

In the field of new energy vehicles, at a time when battery energy density has not yet made a significant breakthrough, reducing the weight of the vehicle has become a realistic path to improve endurance. According to industry research data, for every 10% weight reduction of the vehicle, the vehicle endurance can be increased by about 5%~7%. As a typical lightweight metal material, aluminum alloy can reduce weight by more than 50% compared with traditional steel parts, while still maintaining sufficient structural strength, impact resistance and thermal stability.

When applied to electronic control systems, die-cast aluminum housings can significantly reduce the mass of the control module while ensuring good protection for the internal core components, thereby reducing the load pressure on the chassis and battery system, contributing to the "slimming" of the entire vehicle. This weight reduction effect is particularly evident in key locations such as electric drive systems and electronic control cooling modules, and has become a technical direction of concern for vehicle manufacturers.

Lightweight metal housings not only reduce the weight of the module itself, but also facilitate the miniaturization and structural integration design of the control system. In applications such as compact cabins, intelligent robots, and high-speed industrial equipment, electronic control modules are often faced with space constraints. Aluminum alloy die-castings support thin-wall design and complex geometric one-piece molding, which can reduce volume while ensuring heat dissipation and structural strength.

The surface of the die-casting can be directly reserved for structural functional components such as wire grooves, electrical connection holes, and fixed positions, which is conducive to cable wiring, module stacking and later assembly, and improves the overall integration. This lightweight, compact, and functionally integrated design method is gradually replacing the traditional "split + welding + fixing" solution, and is particularly suitable for highly integrated modules such as intelligent electronic control, sensor fusion, and power conversion.

Typical applications: Application cases of highly integrated and lightweight die-casting parts in vehicle control modules

In the electronic architecture of new energy vehicles, die-cast aluminum housings are widely used in the following control modules:

BCM (body control module): integrated with lighting, door locks, air conditioning and other body control systems, requiring strong shock resistance and anti-interference, aluminum die-cast housings provide both structural support and electromagnetic shielding functions;

MCU (electric drive control unit): the core control center located between the motor and the battery pack, with high heat generation, light weight and high heat dissipation performance, aluminum die-casting just meets the requirements;

OBC/CDC (intelligent charging and current conversion controller): installation space is limited, and there is a high dependence on lightweight housing and integrated heat dissipation design;

After using aluminum alloy die-cast housings, these modules not only achieve overall weight reduction and improved heat dissipation efficiency, but also reduce system complexity and later maintenance costs, which is a typical embodiment of the lightweight concept in practical scenarios.

The supporting role of die-casting technology: full-chain empowerment from material weight reduction to structural optimization

The lightweight properties of aluminum alloy itself are only the basis. To truly achieve effective weight reduction, it is also inseparable from the technical support of die-casting technology in structural integration, thin-wall design, and redundancy elimination. Through die-casting, multiple parts can be combined into an integral structure, reducing fasteners and assembly links, and achieving component modularization and lightweight synchronization. In addition, aluminum alloy die-casting is suitable for batch manufacturing, taking into account both manufacturing costs and design complexity, which is impossible to achieve with traditional CNC processing or sheet metal forming.

Electromagnetic shielding: natural shielding structure to ensure signal security and stability

Modern electronic control systems integrate a large number of high-speed computing chips, wireless modules and high-frequency signal channels. They are extremely susceptible to electromagnetic interference or emit their own interference in complex electromagnetic environments, resulting in communication distortion, system restart, performance degradation, or even complete failure.

Aluminum alloy die-castings have natural electromagnetic shielding capabilities due to their continuous conductive metal structure, closed shell shape and controllable wall thickness design, making them one of the preferred materials in control system shell design.

Shielding principle: The metal shell forms a "Faraday cage" type protective layer

Aluminum alloy has excellent electrical conductivity (generally 3.5~6.3×10⁷ S/m), which can form a closed structure similar to a "Faraday cage" in electronic control systems and has natural electromagnetic shielding capabilities. The metal shell can effectively reflect and absorb external electromagnetic waves, block high-frequency interference signals from entering the system, and inhibit the leakage of the device's own electromagnetic radiation, thereby providing stable and reliable shielding protection for wireless communication, CAN/LIN bus, Bluetooth, Wi-Fi and other signal channels. In high-frequency and high-speed digital signal processing and PWM control, aluminum die castings can also effectively suppress problems such as electrical coupling and signal bounce, ensuring signal integrity and communication stability. Compared with plastics or other non-metallic materials, aluminum alloy housings have irreplaceable electromagnetic protection advantages in scenes that are extremely sensitive to signal environments, such as automotive electronics (such as ADAS, V2X modules), industrial controllers, and 5G communication equipment.

Multiple advantages over plastic and sheet metal structures

Comparison Dimension	Aluminum Die-Cast Parts	Engineering Plastic Housings	Sheet Metal Bending Parts
Shielding Performance	Excellent, forms a fully enclosed metal structure	Requires conductive paint or fabric, prone to aging	Has welds and joints, prone to EMI leakage
Structural Integration	High, can integrate brackets, grounding posts, thermal channels	Moderate, mold-supported but with weaker strength	Low, usually modular with poor shielding consistency
Mass Consistency & Assembly Efficiency	High, stable dimensions suitable for automated assembly	Moderate, thermal deformation may affect fit	Moderate, prone to deformation, requires manual adjustment

Cost-effectiveness: Mass production has obvious advantages, and the cost per piece is only 1/5 of CNC.

Although high-pressure die casting requires expensive mold costs in the early stage, as the output increases, its unit cost will be rapidly diluted, which is much lower than the traditional CNC processing method (CNC). Therefore, die casting is very suitable for the manufacture of medium and high-volume electronic control system products. Its cost advantages are mainly reflected in the following aspects:

Saving processing procedures: The die casting process can complete the overall molding of complex geometric structures through one injection molding, without the need for multiple turning, milling, drilling and other operations like CNC processing, which greatly reduces the number of processes and processing time. This "one-step" manufacturing method not only improves production efficiency, but also reduces process complexity.

High material utilization rate: Die casting is a near-net forming process, that is, the aluminum alloy melt is directly formed into a shape close to the final part size after being injected into the mold under high pressure. Compared with CNC processing to cut finished products from a whole piece of material, die casting has almost no excess waste, and the raw material utilization rate is as high as more than 90%, which effectively saves raw material costs.

Automated molding + less manual reliance: Modern die-casting production lines are mostly equipped with automatic feeding, automatic mold closing, automatic demoulding and cooling systems, which can achieve long-term stable operation and reduce the frequency and error rate of manual operation. This automation advantage not only improves the single-shift production capacity, but also shortens the overall delivery cycle, which is particularly competitive in the industrial chain that is sensitive to delivery time.

When the product output reaches more than tens of thousands of pieces, the average unit price of die-casting parts can usually be reduced to 1/4 to 1/5 of CNC machined parts, significantly reducing the manufacturing cost of the whole machine. This makes it an irreplaceable preferred manufacturing method in cost-sensitive and tight production rhythm fields such as consumer electronics, automotive electronics, new energy control units and industrial control terminals.

How to produce qualified Die Castings?

The production of high-quality die castings for electronic control systems is inseparable from scientific process control and advanced manufacturing technology. From mold design to final quality inspection, die casting production is a highly integrated and precisely coordinated industrial chain. The following is an in-depth analysis of the four key links:

Mold design: 3D printing + mold flow analysis dual drive to improve molding yield

The mold is the "source controller" of the quality of die castings. By introducing 3D printing technology to quickly make prototype molds, and combining mold flow analysis software for dynamic simulation, the flow path, cooling rate, pore aggregation area and other problem areas of the alloy in the mold cavity can be predicted in advance. In particular, mold flow analysis can perform multiple rounds of optimization on injection speed, gate position, exhaust channel, etc., thereby effectively reducing common defects such as shrinkage, pores, and cold shuts.

Measured data show that the mold design optimized by mold flow analysis can increase the yield of die castings by about 25%, greatly improving the stability and economy of mass production.

Die casting process: cold chamber vs hot chamber, process selection determines materials and precision

In die-casting production, the choice of process mainly depends on the type of metal material used and the structural complexity of the product. According to the different melting points and molding requirements, the die-casting process is roughly divided into two types: cold chamber die-casting and hot chamber die-casting:

Cold chamber die-casting:

Cold chamber die-casting is suitable for high-melting-point metals such as aluminum alloys and magnesium alloys. Although the mold and equipment costs are relatively high, it can achieve high-strength and high-precision molding effects. It is particularly suitable for products with high structural complexity and heat dissipation requirements, such as electronic control units (ECUs) and drive module housings. This process effectively reduces thermal damage and improves internal density and dimensional stability by injecting molten metal into an external insulation furnace and then injecting it into the mold cavity at high speed.

Hot chamber die-casting:

Hot chamber die-casting is suitable for low-melting-point metals such as zinc alloys and lead alloys. Its equipment has high integration, short cycle, and high production efficiency. It is suitable for manufacturing small-sized and simple-structured parts, such as consumer-grade electronic accessories and light-loaded hardware components. Since hot chamber die casting immerses the injection mechanism into the molten metal to directly take the material, the molding speed is fast and the mold cost is low, which is more suitable for large-scale and rapid production applications.

Most die-casting structural parts in electronic control systems are made of aluminum alloy, so cold chamber die casting is more suitable. Although its production cycle is slightly longer, it has obvious advantages in ensuring product structural strength, thermal management performance and long-term stability, and is an irreplaceable die-casting solution for high-end electronic equipment.

Post-processing key: Anodizing provides dual protection of corrosion protection and beauty

Although the aluminum alloy parts after die-casting have good mechanical properties and thermal conductivity, they are susceptible to oxidation, corrosion and wear in the exposed state, especially in high humidity, salt spray or outdoor environments. Therefore, it is particularly important to post-process them on the surface. It is a technology that generates a dense oxide layer on the aluminum surface by electrolysis, taking into account both functionality and decorativeness. It is one of the most widely used and mature post-processing solutions. Specific advantages include:

Enhanced anti-corrosion performance:

The oxide film formed by anodizing has a highly dense and continuous structure, which can effectively block water vapor, salt and chemical corrosive media in the air, and prevent electrochemical reactions in the aluminum matrix. This protective layer not only has excellent weather resistance and performs well in salt spray tests, but also can resist acid and alkali erosion in industrial environments, significantly extending the service life of die-castings. It is particularly suitable for application scenarios such as automotive electronics and outdoor controllers that are exposed to harsh environments for a long time.

Improved wear resistance:

After anodizing, the surface hardness of aluminum parts can be increased to more than 200HV, and some special processes can even reach 400HV, which is much higher than the untreated substrate. This high-hardness coating can effectively resist scratches and wear during daily assembly, transportation and operation. It is especially suitable for electronic control module housings that are frequently plugged and unplugged and contacted. It has significant advantages in high-frequency use scenarios such as industrial automation and rail transit.

Good appearance consistency:

Anodizing can also give the oxide film a variety of high-end metal texture colors such as silver white, matte black, titanium gray, champagne gold, etc. through electrolytic dyeing or chemical coloring processes to meet the appearance customization needs of different customers. At the same time, the anode layer has good adhesion and color uniformity, which can achieve consistent color difference control of large-scale products, so that the product has a high-quality appearance while meeting the protection function. It is widely used in high-end consumer electronics, smart equipment, and automotive-grade electronic housings, etc., which require high brand recognition.

Anodizing is not only a key process to improve the performance of die-cast aluminum parts, but also an important means to give them commercial value and visual appeal, truly achieving a win-win situation of functionality and aesthetics.

Which industries are being applied on a large scale?

With the increasing demand for intelligence, lightweight and high reliability in many industries, aluminum alloy die-castings are being widely used in many key fields due to their excellent structural strength, thermal management capabilities and precision molding characteristics. It is no longer just a single structural support, but has gradually evolved into a multifunctional composite component that integrates protection, heat dissipation, electromagnetic shielding and aesthetics. From the electronic control module of new energy vehicles, to the sealed housing of industrial control systems, to the heat dissipation bracket of photovoltaic inverters, and even the antenna cover of 5G equipment, aluminum alloy die-castings are becoming an important cornerstone to support intelligent manufacturing and high-end equipment upgrades with their outstanding performance. The following four typical application scenarios fully demonstrate the value potential released in different industries.

Automotive electronics: structural + functional integration, helping the implementation of intelligent driving

With the rapid popularization of new energy vehicles and intelligent driving systems, the requirements of automotive electronics for structural parts are moving from "pure protection" to "structural + functional integration". Die-cast aluminum plays a core role in this trend.

Typical case:

Tesla's electronic control unit housing adopts integrated die-casting molding technology to integrate multiple parts into a whole, significantly reducing assembly processes such as welding and screwing, and improving overall rigidity and reliability.

In addition, this type of die-cast housing can also take into account heat dissipation and electromagnetic shielding functions, providing a stable operating environment for key electronic control modules. With the promotion of "super die-casting" technology, the entire automotive electronic architecture is evolving towards lighter, stronger, and more integrated.

Industrial automation: Improved protection level, reliable operation without fear of environmental challenges

Industrial control equipment is often deployed in harsh environments such as high dust, strong electrical interference, high and low temperature alternation, and has extremely high requirements for the protection level of the structural shell.

Typical applications:

The PLC controller housing is made of high-pressure die-cast aluminum, with precision molds and sealing design, which can achieve IP67 protection and protect the core circuit from environmental erosion.

At the same time, the good thermal conductivity of aluminum alloy makes the housing also act as a heat sink, reducing the risk of thermal failure of equipment and extending its service life. In scenes such as automated factories, logistics systems, and CNC machine tools, die-cast housings have gradually replaced traditional sheet metal and plastic housings and become the preferred solution for mid-to-high-end control equipment.

Energy and power: high temperature resistance + corrosion resistance to ensure stable operation of equipment under extreme working conditions

New energy equipment has strict requirements on environmental adaptability, especially in deserts, high altitudes or coastal areas. High temperature, salt spray, ultraviolet radiation and other factors pose great challenges to the equipment housing.

Case analysis:

The heat dissipation housing of photovoltaic inverters adopts a die-cast aluminum structure, which not only provides solid support physically, but also effectively reduces the module temperature through an integrated heat sink design to ensure long-term full-load operation.

With surface treatment processes such as anodizing, the shell can withstand extreme climates of -40℃ to +85℃, and has excellent corrosion resistance. It can be stably used for more than 10 years even in high humidity and high salt environments. It is one of the key components to improve the stability of photovoltaic power stations.

Consumer electronics: lightweight + heat dissipation balance to meet the performance requirements of the 5G era

With the implementation of new generation technologies such as 5G, AIoT, and edge computing, consumer electronic devices are showing the characteristics of "small size, high power, and dense deployment", which puts higher requirements on heat dissipation capacity and weight control.

Representative case:

The 5G base station AAU antenna cover is made of aluminum alloy die-casting, which achieves lightweight structure while incorporating heat dissipation design elements such as fins and vents, effectively alleviating the problem of high-power heating.

In addition, the die-cast shell also takes into account the electromagnetic shielding function to reduce interference with peripheral equipment. While ensuring communication stability, it meets the use environment that is extremely sensitive to weight, such as high-altitude tower installation.

How will Die Castings evolve?

Material innovation: High silicon aluminum alloy promotes the dual improvement of thermal conductivity and lightweight

Traditional aluminum alloys can no longer meet the heat dissipation requirements under high heat load scenarios, especially in the fields of 5G communication equipment and new energy vehicle power devices. High silicon aluminum alloys are becoming the key breakthrough direction of the new generation of die casting materials.

Improved thermal conductivity:

Thanks to the uniform distribution of silicon particles and optimized crystal structure, the thermal conductivity of high silicon aluminum alloys can reach 180~220W/m·K, which is nearly 50% higher than that of ordinary aluminum alloys, significantly optimizing the heat dissipation efficiency.

Reduced thermal expansion coefficient:

The high silicon content gives it a thermal expansion performance close to that of ceramics, which is conducive to matching with ceramic substrates and chip packaging structures, and improving stability under long-term thermal cycles.

Adaptation to highly integrated systems:

High strength and high dimensional stability also make it suitable for the packaging of high-density electronic structural parts such as new energy vehicle IGBT modules and AI computing units.

2. Intelligent manufacturing: IoT die-casting machines enable precise control of the entire production process

Under the wave of Industry 4.0, die casting is no longer a "black box" processing technology. Represented by companies such as Lijin Technology and Buhler, more and more die-casting machines are introducing the Internet of Things and AI control systems to promote the upgrade to "smart die-casting".

Real-time parameter control:

 Sensors monitor key indicators such as mold temperature, injection speed, and alloy liquid temperature. The system can adjust the pressure and clamping force in real time to achieve dynamic compensation and avoid defects such as pores and cold shuts.

Predictive maintenance:

With the help of data analysis and edge computing technology, equipment operation abnormalities and mold wear trends can be identified in advance to reduce unplanned downtime.

Quality traceability system:

Each mold data record can be linked to the final product to achieve full process traceability, especially suitable for fields with high reliability requirements such as automotive electronics and aviation components.

3. Green production: high proportion of recycled aluminum + low-carbon process promotes sustainable transformation

The global carbon neutrality trend and the EU carbon tariff (CBAM) mechanism force the die-casting industry to accelerate green transformation. Through technical optimization and resource recycling, the proportion of recycled aluminum applications continues to increase, becoming an important path for carbon reduction in the industry.

Recycled aluminum accounts for more than 80%:

Driven by the continuous progress of smelting and purification technology, the purity and performance of recycled aluminum are comparable to those of primary aluminum, while its carbon emission intensity is only 1/10 of that of primary aluminum.

Low-carbon manufacturing process:

 including the use of electric heating furnaces to replace gas smelting and the application of more energy-efficient servo die-casting machines, the overall unit energy consumption is reduced by more than 20%.

Transparency of carbon footprint:

More and more export companies are actively establishing carbon data systems to meet the audit requirements of the EU CBAM and enhance the environmental competitiveness of the global supply chain.