Falcon’s aluminum die casting parts achieve ±0.005mm tolerances for automotive EV battery trays and robotic joint housings, using high-pressure vacuum casting to reduce porosity by 80%. Our ADC12 and A380 alloys meet IATF 16949 standards for transmission housings, while 6061-T6 medical-grade components undergo ISO 13485-certified cleanroom machining for surgical instruments. For 5G RF modules, EMI-shielded enclosures with hard-anodized finishes ensure MIL-STD-461G compliance, validated in field trials.
Automotive Industry
Falcon’s high-pressure die-cast EV battery trays reduce weight by 18% using ADC12 alloy, supporting 50,000-unit/month batches with <0.1mm dimensional variance. For turbocharger housings, 5-axis CNC post-processing ensures ±0.005mm precision, critical for car manufacturer supply chain.
Electronics & Communications
5G RF module enclosures leverage 6061-T6 alloy for 25% thermal efficiency gains, combining EMI shielding coatings and vacuum casting to eliminate signal interference. Our CNC-machined heat sinks achieve 0.1°C/mm² thermal gradient, tested in 5G.
Medical & Robotics
ISO 13485-certified titanium-aluminum hybrid joints for surgical robots undergo 10,000-cycle fatigue tests, reducing friction by 15%. For drone frames, 7075-T6 die-cast chassis achieve 5-day lead times with automated CMM inspection.
Casting of aluminum parts involves the process of pouring molten aluminum into a mold to create a specific shape. This method, known as aluminum casting, is commonly used to manufacture complex components for various industries. There are different casting techniques, with die casting being a prominent method for producing precise and detailed aluminum parts.
Die-cast aluminum parts are typically made from aluminum alloys, which are blends of aluminum with other metals to enhance specific properties. Common alloying elements include zinc, copper, and magnesium. These alloys offer a good balance of strength, durability, and light weight, making them suitable for a wide range of applications.
The die casting process for aluminum involves injecting molten aluminum into a steel mold, known as a die, under high pressure to produce aluminum machining parts. This pressure ensures that the liquid metal fills the mold cavity, creating a detailed and accurate replica of the desired part. Once the aluminum solidifies, the mold is opened, and the finished part is ejected. This process is highly efficient for producing intricate and high-precision aluminum components used in industries such as automotive, aerospace, and electronics.
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