Optics Die Casting
Elimold’s optical die casting services offer a cost-effective way to produce metal parts that can be easily and efficiently handled for large-scale production. Our processes ensure that each part meets high standards, providing quality and consistency at an affordable price. Contact us now for a quote.
Optical Parts Die Casting Services on Demand
Elimold is your trusted partner for precision die casting solutions for optical components. With a commitment to excellence and a proven track record of delivering best-in-class products, we are your first choice for high-quality custom components for the custom optics industry.Our professional die casting services are designed to meet the unique needs of the optical industry, ensuring that every part we produce meets the highest standards of quality, durability, and precision. With a team of experienced engineers, state-of-the-art facilities, and a passion for innovation, Elimold prides itself on its ability to turn your design ideas into reality. Whether you need complex optical housing assemblies, heat sinks, reflectors, or other complex parts, we have the expertise and technology to turn your ideas into reality.What sets us apart is our unwavering commitment to customer satisfaction. We work closely with our customers to understand their specific requirements and custom our services to their needs. Our rigorous quality control process ensures that every part is thoroughly inspected before it reaches you, ensuring seamless integration into your optical system.From prototyping to production, Elimold is with you every step of the way. Our streamlined production process, attention to detail, and dedication to on-time delivery make us a reliable partner for your die casting needs.
Our Optical Die Casting Capabilities
Elimold offers high-precision optical die casting services capable of producing challenging, complex micro or small functional parts. We offer a wide selection of advanced machines capable of 250 to 700 shots per hour, 7 to 2,500 metric tons of clamping pressure, and shot weights up to 20 pounds. Part sizes are up to 24 inches long and 24 inches wide. Manufacturing is done using a versatile, efficient high-pressure die casting process that consistently maintains tolerances of ± 0.0005 inches. Typical lead times are 4 to 6 weeks, handling small to large batches. Elimold has developed a concurrent engineering process that optimizes quality and productivity, resulting in a cost-effective and reassuringly consistent production experience.
Post-casting operations include machining, tapping, grinding, and vibratory milling. Surface treatment options include polishing, painting, electrophoresis, and plating. All production takes place on site at our ISO 9001:2008 certified factory and every part undergoes a comprehensive quality assurance protocol and thorough testing and inspection, including optical comparator testing.
Our Manufacturing Services
Elimold offers best-in-class manufacturing capabilities, ideal for rapid prototyping and custom production orders. With our own facilities and extensive manufacturing network, we are able to efficiently deliver complex, high-quality parts.
Sand Casting
Investment Casting
Die Casting
Low Pressure Casting
Permanent Mold Casting
Lost Foam Casting
Centrifugal Casting
Vacuum Casting
Squeeze die casting
Our Optical Die Casting Service Qualifications
With Elimold, you can enjoy the best advice and practical solutions for optical die casting molds and mass production of optical die casting parts. We offer a wide range of tolerances, materials and surface treatments for our customers’ die-cast metal optical products. In addition, our professional engineers ensure that complex casting components are manufactured with fast delivery times and excellent efficiency. Our professional management team allows customers to upload optical die casting design files online and allows them to track their orders at every stage of manufacturing, providing customers with a high level of satisfaction. Most importantly, Elimold follows strict quality control standards to inspect the quality of die castings at different manufacturing stages before and during production. Therefore, you can trust us to provide excellent quality, high precision and cost-effective parts for optical die casting models.
Rapid Prototyping
Elimold is committed to turning your dreams into reality. We provide rapid prototyping services to help you quickly turn your ideas into reality. Using advanced die casting technology, we can produce prototypes that accurately represent the final optical product. And when it comes to rapid prototyping, we can provide you with the products you need in 1/2 less time than other manufacturers and provide the highest quality assurance. This allows you to test and improve your designs before full production. Our rapid prototyping services in Shenzhen, China help you save time and money while ensuring that your parts meet all necessary requirements. Trust us to provide high-quality optical product prototypes to help you move forward with confidence.
Optical Die Casting Tooling
Our state-of-the-art in-house tool shop enables us to provide a complete solution from tool design, manufacturing, modification and maintenance to the final management of the tooling. Elimold has many years of experience in die casting tooling manufacturing, which is reflected in the quality of your final product and tooling. Our rapid tooling service takes only 2-4 weeks or less, depending on your quantity and requirements. Advanced equipment and machinery give us the ability to provide world-class services in the manufacture of any mold or tooling.
Our Advantages
We have a strong team and long-term partnership network with experienced and skilled finishing shops and suppliers to support machining and finishing specifications. We can provide you with extraordinary flexibility, responsiveness, delivery performance and customer service within a well-structured supply chain by managing a wide range of finishing and machining capabilities in the most efficient way. While creating a win-win situation, our customers will ultimately gain obvious benefits:
- Simplified Inventory Management
- Inventory Reduction
- Minimal Logistics Management for You
- Lower Labor Costs
- Reduced Shipping Lead-times
- Increased Opportunities to Greater Market Share Gain
- Streamlined Dock-to-Stock Program (delivery of products directly to point-of-use)
Custom Die Casting Solutions for Your Unique Optical Industry Project Needs
At Elimold, we offer a variety of die casting processes tailored to your optical project needs, ensuring our parts perform flawlessly in their intended environment. Our custom die casting services are ideal for optical component manufacturers seeking unique, high-performance designs. Our team of experts will work closely with you to find the best solution for your project.
Machining and Design of Complex Optical Parts
After choosing the right metal for your optical project, creating superior design and tooling is just as important. When Elimold is involved in the early stages of your design process, our engineers can help you leverage our die casting tooling technology. When you use our multi-slide technology, the molds have more flexibility in the direction of pull, allowing more complex parts to be manufactured consistently without as many secondary operations, reducing the cost per part.
Making Relatively Complex Shapes
At Elimold Die Casting Services, we specialize in producing complex shapes that are difficult to achieve with other methods. Die casting allows us to create complex designs with a high degree of precision, making it ideal for components with detailed features. Whether it’s thin walls, complex curves, or intricate patterns, our advanced die casting technology ensures your optical parts are exactly the way they need to be. This ability to produce complex shapes without sacrificing quality makes die casting a versatile solution for the optical industry.
Incredible Dimensional Stability
Dimensional stability is critical in the optical part manufacturing process, and Elimold Die Casting Services excels in this area. Our die casting process ensures that each component maintains precise dimensions, even in high-volume production. This consistency is critical for components that must fit perfectly or operate reliably under pressure. By maintaining tight tolerances and minimizing shrinkage or warping, we deliver components that meet your specifications, ensuring your components are perfect and reliable.
Creating Lightweight Components
Elimold Die Casting Services is known for making lightweight and durable optical components. Our die casting process allows us to use metal materials such as aluminum and magnesium, which are stronger but lighter than other metals. Reducing weight can increase efficiency and performance in the optical industry. Despite their light weight, our die-cast parts do not compromise on strength or integrity.
Our on-demand manufacturing capabilities for optical components
Elimold offers sand casting, die casting and investment casting processes for optical components to ensure consistent quality assurance. We also provide services ranging from simulation verification to accelerated tool trials and first-article inspection to production control and CNC machining. And we also allow inspection planning based on design data. In model and mold making, tools and patterns can be corrected in a targeted manner and the fit of mold halves, cores and slides can be checked. During the trial process, the shape and size of the castings are checked: part geometry, material thickness, shrinkage and warpage. All measurement and inspection processes are automated to control production quality.
Part Design (CAD/PMI)
Elimold’s CAD models for optical parts are already equipped with inspection capabilities during the design process, allowing for 3D measurement planning and inspection to be performed directly without drawings. In addition, we also allow the re-entry and adjustment of component and tool geometries into existing CAD data if mold correction is required using advanced CAD modeling. The acquired 3D measurement data can also be used to create design data in the field of reverse engineering.
Simulation & Validation (CAE)
Our simulation service can be used to calculate and visualize mold filling, gating, holding pressure, temperature control and filling times for castings. The aim is to prevent errors and optimize material usage, cycle times and machine dimensions by predicting process parameters and material behavior using the ARAMIS system during material testing. Our service also measures the geometry of the actual component and compares it digitally with the simulation data to optimize and validate the simulation model.
Tool Manufacturing
Our 3D digitalization technology saves time and costs in the manufacturing and maintenance of optical die casting molds. During the CNC machining of die casting molds and electrodes, wax and ceramic cores and sand core boxes, Elimold controls the individual manufacturing steps at an early stage by comparing nominal and actual data, thus reducing iteration cycles, especially for multiple cavities. During the tryout process, we use the 3D data to locate mold correction areas.
Patternmaking
Systematic shape and dimensional control of wax and foam patterns, wax components, templates and equipment ensures and accelerates mold production and subsequent process steps in the casting process. By controlling the milling results at an early stage, possible errors in templates and template equipment can be identified and eliminated.
Mold Making
In optical die casting mold manufacturing, we measure molds and cores made of materials such as sand or ceramic to ensure process quality. Elimold’s mold and core measurement data enables virtual assembly analysis of mold halves and cores, which can be used to check the offset, fit and shape fit of the mold halves and core gaps of the parting surfaces. In investment casting, the wall thickness of ceramic molds can be checked to assess their quality and burr formation.
First Article and Series Inspection
We can perform first article inspection based on CAD models or PMI data sets and CMM inspection using features such as GD&T. Our QC team performs full-field 3D inspections, leaving no part area unchecked. In quality control of series production, the QC team reduces scrap and rework time through automated, production-related and mobile measurement cells. Parts do not need to be transported to a remote measurement room.
CNC Machining
Elimold’s team uses back projection to project features such as contours and punch marks directly from the software onto the actual part. As a result, traditional marking of heavy castings is no longer necessary. Efficient part alignment for CNC machining is possible. In addition, the use of 3D measurement data provides the basis for on-demand manufacturing processes such as CNC machining.
Importance of Post-Casting Testing for Optical Components
Small precision optical die cast components, in particular, require exceptional quality and consistency. Therefore, it is important to implement controls to avoid dimensional, internal, and surface defects. For thin-walled and complex components, you need to know that the part will not easily crack or wear out over time, especially under harsh environmental conditions such as high temperature and high humidity. Working with an optical component die cast manufacturer to complete accelerated life testing to ensure your parts are qualified is critical to the success of your project.
Elimold’s experience and resources provide our optical industry customers with a wide range of design, manufacturing, and value-added services, such as surface protection treatments. Our success in manufacturing optical components has helped us establish partnerships with some of the industry’s leading suppliers. If you are looking to provide quality components to the growing optical industry, it is important to work with quality suppliers. Contact one of our engineers today to discuss your next project.
Material Selection
The main die casting alloys are: aluminum, zinc, magnesium, copper, lead, and tin; although less common, ferrous metal die casting is possible. Specific die casting alloys include: zinc aluminum; aluminum, such as those that meet the Aluminum Association standards: AA 380, AA 384, AA 386, AA 390; and AZ91D magnesium.
- Aluminum: Lightweight; High dimensional stability for very complex shapes and thin walls; Good corrosion resistance; Good mechanical properties; High thermal and electrical conductivity; Retains strength at high temperatures.
- Zinc: Easiest metal to cast; High ductility; High impact strength; Easily plated; Economical for small parts; Extended die life.
- Magnesium: Easiest metal to machine; Excellent strength to weight ratio; Lightest commonly used die casting alloy.
- Copper: High hardness; High corrosion resistance; Highest mechanical properties of die casting alloys; Excellent wear resistance; Excellent dimensional stability; Strength approaching that of steel parts
- Silicon copper alloy: High-strength alloy made of copper, zinc, and silicon. Often used as a replacement for precision cast steel parts.
- Lead and Tin: High density; extremely high dimensional accuracy; used for special forms of corrosion resistance.
Multiple Finishes
Your design specifications and expectations are what drives the process. Whatever your finished form needs, we are equipped to provide you with the service you need to attain a competitive advantage in your industry. The finishing services we offer are:
- MicroarcOxidation (MAO)
- Anodizing
- Bead Blasting
- Powder Coating
- Electroplating
- Polishing
- Brushing
- Electrophoresis
- Painting
- Vibratory Deburring
- Rotoblast/Shot-Blast
- Impregnation
- E-Coating
Providing precision die casting expertise to various industries
Elimold is a trusted supplier of high-quality die castings for a wide range of industries. We are a trusted partner in the field of die casting with a focus on precision, innovation and customer satisfaction.
With many years of experience, we know the die casting process inside out, so we are able to manufacture the highest quality parts. Our expertise covers a variety of industries, including automotive, aerospace, electronics and more. Whether you need lightweight automotive parts or delicate electronic components, Elimold can meet your needs.
Ready to start your next optical die casting project?
At Elimold, we provide precision optical die casting products with highly complex geometries. To learn more about our services or get started with a custom solution today, contact us or request a quote.