Shata is a professional die-cast aluminum products supplier, offering custom die cast aluminum heat sink for diverse industries.
Based on our previous experiences cooperating with our clients to develop die cast aluminum heat sink, the purchasing engineers always have problems with supplier choosing and price negotiation, the design engineers always have problems with structural optimization and performance adaptation. The following conversation may help purchasing engineers and design engineers address the core pain points in the procurement and design of die cast aluminum heat sink.
Customer from a certain electronic equipment manufacturing company:
Daron: Purchasing Engineer
Mike: Design Engineer
Shata:
Marina: Sales Manager
Brian: Production & Technology Engineer
Design Pain Point: Imbalance Between Space and Heat Dissipation Performance – How to Balance Adaptability and Efficiency?
Mike (Design Engineer, Customer): Hi Brian, currently we are developing a new industrial controller and need to customize a die cast aluminum heat sink.
However, the internal space of the controller is limited, it requires a compact structure of the heat sink. Heat dissipation efficiency is not enough.
We finally got a version with good heat dissipation efficiency, but most of our suppliers said it is difficult to mass production, as the structural limitations of die casting. Do you have any idea to solve this problem?
Brian (Production & Technology Engineer, Shata): Hi Mike, this is the most common contradiction in the design of die cast aluminum heat sink.
It is indeed limited by the mold and fluidity for die casting. Some extremely irregular structures may lead to serious defects. We can optimize it from two aspects, material and structural.
Firstly, we consider using die cast aluminum alloys with excellent fluidity, such as ADC12 or A380. They can balance structural complexity and forming stability.
Then we do structural optimization. Shata can provide DFM (Design for Manufacturability support. According to mold design and mold flow analysis, we provide you accurate suggestions, such as the maximum height, the minimum thickness of fins, the dense of fins, the minimum draft angle you can use, to maximize the heat dissipation area as much as possible.
In addition, for irregular structures, our mold team can achieve batch production of some complex structures by optimizing the gate position and exhaust system.
Previously, the compact die cast aluminum heat sink customized for a new energy charging pile customer increased the heat dissipation efficiency by 25% through this method, while also meeting the space limitations.
Mike (Design Engineer): I see. You provide design simulation services, correct? We hope to verify the mold before manufacturing to avoid increased costs due to subsequent mold modifications.
Another question, what is the minimum wall thickness of the die cast aluminum heat sink you produce? Will it affect the structural strength and heat dissipation performance?
Brian (Production & Technology Engineer): Yes, we provide mold flow analysis to avoid further modifications.
Usually, our minimum wall thickness is 2mm, with enough structural strength and good quality. Below picture is a minimum 2mm thickness die cast aluminum heat sink we produced before.
Process Pain Point: Surface Finish and Anti-Corrosion Requirements - How to Adapt to Complex Working Conditions?
Mike (Design Engineer): Brian, another question. What kind of surface finish can you offer?
Brian (Production & Technology Engineer): We can offer four common solutions to meet different needs: powder coating, electrophoretic coating, anodizing and hard anodizing.
Currently, we are testing a new surface treatment - Teflon coating - for an LED lighting customer. The Teflon coating has a minimal impact on heat dissipation efficiency and is resistant to strong acids and alkalis, making it suitable for use in extreme environments. The drawback is that the cost is extremely high.
Procurement Pain Point: How to Control Quality and Delivery Cycle?
Daron (Purchasing Engineer): Marina, apart from the design issue, we also have questions about procurement process. How do you ensure consistent product quality and on-time delivery?
Marina (Sales Manager): In terms of quality control, we have established a complete quality control system, including raw material incoming inspection, real-time production parameters monitoring during casting, multiple delivery inspections such as X-ray detection, air tightness testing, and dimensional measurement. Substandard products are rejected to ensure the consistent quality of bulk products.
In terms of delivery cycle, we have a strong production capacity with a large number of die-casting machines, clamping force from 150 ton to 2,000 ton and 3,000 ton, all of them can meet the production demands of large and high strength die casting.
Meanwhile, we have multiple automated die-casting lines, which can complete at least 3,000 clamping cycles every day.
Daron (Purchasing Engineer): What about the price? What is your advantage in quotation? Will there be a situation of "low price with low quality"?
Marina (Sales Manager): Our price advantage comes from large-scale production and refined cost control. We have signed long-term cooperation agreements with raw material suppliers to obtain stable raw material prices.
Meanwhile, the automation rate of our production line has reached 80%, reducing labor costs and enhancing production efficiency.
Therefore, we can offer high cost-performance quotations while ensuring quality.
Adaptation Pain Point: Consistency Between Samples and Mass Production - How to Reduce Risks?
Daron (Purchasing Engineer): Will there be a situation where the samples are good, but the bulk goods are not?
Marina (Sales Manager): We promise samples will be made with same raw materials, molds and process parameters as those used in mass production, to ensure they can truly reflect the performance of the batch products.
Small-batch trial production is also a good way to allay customers' concern. We can produce 50 to 100 small-batch products for installation testing and quality re-inspection.
We strictly follow the process standards that have been verified through trial production and conduct random inspections every two hours to increase the inspection frequency and ensure the stability of batch production.
Are you also facing challenges in the procurement or design of die cast aluminum heat sink? Send email to Shata at any time, our professional technical team is pleased to communicate with you.
Get a tailored die-casting solution: info@shatamachinery.com
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