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2025 Die Casting Smart Manufacturing Trends: Flexibility, Digitalization, and Greenness Stand as a Triad

2025 Die Casting Smart Manufacturing Trends: Flexibility, Digitalization, and Greenness Stand as a Triad

In 2025, the die-casting automation industry will exhibit three major trends: flexible manufacturing will enable adaptation to multi-variety production, and modular systems will generally reduce changeover times to under two hours; digitalization will deepen its penetration, with the integration of Manufacturing Execution Systems (MES) and industrial big data boosting decision-making response speeds by 30%; and green production will become a pressing necessity—technologies such as furnace waste heat recovery and automated scrap compression will help companies cut carbon emissions by 15%. Industry experts point out that companies possessing both flexible integration capabilities and advanced digital solutions will gain a competitive edge in high-end sectors such as new-energy vehicles and aerospace.

2025-10-11

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Die Casting Automation Operation and Maintenance Guide: The Three Key Factors for Reducing Equipment Failure Rates

Die Casting Automation Operation and Maintenance Guide: The Three Key Factors for Reducing Equipment Failure Rates

The stable operation of automated equipment hinges on scientific operations and maintenance. A “predictive maintenance solution” launched by specialized manufacturers leverages IoT systems to collect vibration and temperature data from equipment such as robots and die-casting machines, and uses AI algorithms to proactively warn of potential failure risks. After implementation by a hardware enterprise, the downtime caused by equipment failures was reduced from 12 hours per month to just 2 hours. Moreover, the establishment of a standardized spare parts library and a remote diagnostic system has enabled the average repair time to be kept within 4 hours, ensuring efficient operation of the production line.

2025-10-11

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Data-Driven Die-Casting Plants: How MES Systems Break Down Management Barriers

Data-Driven Die-Casting Plants: How MES Systems Break Down Management Barriers

Manufacturing Execution Systems (MES) are becoming the “central nervous system” of smart die-casting factories. One company, by deploying an MES system, has achieved digitalization across the entire process—including planning management, equipment management, and quality management. The system collects key parameters such as pressure and temperature from die-casting machines in real time and generates visual dashboards, boosting workshop response speed by 50% and raising order delivery accuracy to 99%. Industry experts emphasize that seamless integration of MES with systems like SAP and WMS is crucial for achieving synergy across “design, manufacturing, and management.”

2025-10-11

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16,000T Ultra-Large Die-Casting Island Technology Breakthrough: Perfectly Suited for the Integrated Needs of New Energy Vehicles

16,000T Ultra-Large Die-Casting Island Technology Breakthrough: Perfectly Suited for the Integrated Needs of New Energy Vehicles

With the surging demand for integrated die-cast components in new-energy vehicles, a major breakthrough has been achieved in 16,000-ton-class die-casting island technology. A super-large die-casting island system developed by a certain enterprise consists of 12 standard modules and is equipped with a self-developed inspection-assistance device, boosting inspection efficiency by 50%. This system has already been successfully supplied to multiple automakers, enabling the company to achieve an annual production capacity of 200,000 sets of aluminum alloy subframes. The key technologies behind this system lie in the coordinated control between robots and die-casting machines, as well as the integrated application of post-processing modules such as laser cleaning and deburring.

2025-10-11

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Integrated peripheral equipment for die casting: Small components drive high efficiency.

Integrated peripheral equipment for die casting: Small components drive high efficiency.

The integrated application of peripheral equipment such as automated feeding machines and spray devices is becoming a key factor in enhancing die-casting efficiency. Specialized manufacturers have introduced integrated peripheral equipment systems that, when coordinated with six-axis robots, achieve precise operations with a feeding speed of just 0.3 seconds per cycle and a spray coverage rate of 98%. On a certain 3C electronic component production line, this system boosted the overall equipment effectiveness (OEE) from 65% to 82% and reduced labor costs by 60%. Industry experts point out that standardized interfaces and modular designs for peripheral equipment are the foundation for realizing full-line automation.

2025-10-11

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Implementation of unmanned die-casting lines: From “dark factory” production to full-cycle traceability

Implementation of unmanned die-casting lines: From “dark factory” production to full-cycle traceability

The unmanned die-casting line developed by a certain enterprise has achieved full-process automation—from metal liquid molding to laser cutting. By seamlessly integrating six-axis robots with die-casting machines and inspection equipment, this production line enables 24-hour continuous operation. Its production capacity is three times higher than that of traditional lines, and the defect rate has dropped by 90%. Even more noteworthy is that, combined with a WMS and IoT system, the product lifecycle—from raw materials to finished goods—can be fully traced, completely meeting the quality control requirements of the automotive industry.

2025-10-11

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Industrial Furnaces and Automation Systems Working in Synergy: Solving the Challenges of Die Casting Temperature Control

Industrial Furnaces and Automation Systems Working in Synergy: Solving the Challenges of Die Casting Temperature Control

Precise temperature control in industrial furnaces directly affects the quality of die-cast parts, and automation integration is now enabling this breakthrough. Professional manufacturers are achieving precise control of aluminum melt temperatures—within ±5℃—by linking furnaces with six-axis robots and intelligent sensing systems. Combined with real-time data feedback from MES systems, this approach has reduced the defect rate of battery housings for a certain automaker by 2%. Moreover, automated furnace charging and waste-heat recovery modules can cut energy consumption by 18%, balancing production efficiency with environmental sustainability requirements and making them a key configuration in the new-energy die-casting sector.

2025-10-11

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How can flexible manufacturing adapt to the demand for multi-category die casting? Modular technology provides the answer.

How can flexible manufacturing adapt to the demand for multi-category die casting? Modular technology provides the answer.

Faced with market demands for “multiple varieties and small batch sizes,” modular integration has emerged as a new direction in die-casting automation. A certain enterprise has developed a die-casting island system ranging from 650T to 16,000T, which achieves rapid switching among functions such as part removal, spraying, and inspection through the flexible combination of 12 standard modules. After adopting this solution, a certain new-energy vehicle manufacturer reduced its motor housing production line’s changeover time from 8 hours to just 1.5 hours, while boosting equipment utilization to over 90%. It is reported that such modular systems can cut retrofitting costs by 15% and shorten installation periods by 40%, and are now widely suited to production needs across multiple sectors, including automotive and 5G electronics.

2025-10-11

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Unlocking the Smart Die Casting Factory: A Full-Chain Upgrade from Equipment Connectivity to Intelligent Decision-Making

Unlocking the Smart Die Casting Factory: A Full-Chain Upgrade from Equipment Connectivity to Intelligent Decision-Making

The transformation practices of a certain aluminum enterprise have revealed the key to building a smart factory. By integrating equipment such as die-casting machines, industrial furnaces, and six-axis robots, the company has established a comprehensive, end-to-end system that includes an MES manufacturing execution system, an intelligent WMS warehouse management system, and AGV-based logistics. After production data is collected in real time via an IoT system, it is analyzed and presented by a BI platform, shortening the order delivery cycle by 40% and smoothly achieving the annual target of producing 200,000 sets of aluminum alloy subframes. Industry experts point out that the construction of a smart factory must emphasize the “integration of four modernizations”—equipment automation forms the foundation, data informatization is the core, process intelligence is the goal, and lean management serves as the guarantee.

2025-10-11

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Six-axis robots break through bottlenecks in die casting production!

Six-axis robots break through bottlenecks in die casting production!

In high-temperature and high-humidity die-casting workshops, six-axis industrial robots are increasingly becoming the mainstay of production. The QJR20-2 six-axis robot launched by Zhejiang Qianjiang Robot, with its IP67 protection rating and a repeat positioning accuracy of ±0.05 mm, integrates part removal, spraying, and inspection into a single, seamless operation for die-cast parts. Equipped with a long-stroke centering gripper and four adjustable spray nozzles, this robot can handle multiple product specifications. When switching between different products, only the program parameters need to be adjusted, enabling one automotive component manufacturer to increase its production takt time by 40% and reduce mold-release agent consumption by 30%. Industry experts point out that the flexible application of six-axis robots has become a key lever for die-casting companies to reduce costs and improve efficiency.

2025-10-11

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