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Die Casting Mold Manufacturing Verification Techniques and Mold Optimization

Our mold design team utilizes the latest engineering technologies and mold flow analysis tools, including flow simulation technologies and other engineering software such as Anycasting/Pro-Engineer/CREO & AutoCAD. These are crucial in die casting mold manufacturing and die casting production, ensuring the success of your project.

Advanced Technical Die Casting Mold Design Team

Our team of experienced mold engineers specializes in concept visualization, functional analysis, mold flow analysis, and comprehensive mold design. This approach helps to prevent the most likely issues during mold manufacturing and aluminum die casting production processes.

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As a professional Chinese die casting mold manufacturer, Honjenny Metal offers complete services in mold design, manufacturing, verification, maintenance, and care. We are always ready to respond quickly to your die casting mold manufacturing and aluminum die casting production needs.

Partial Die Casting Products



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Equipment NameEquipment Model/SpecificationQuantity
Zinc Alloy Die Casting Machine160T4
Zinc Alloy Die Casting Machine200T1
Zinc Alloy Die Casting Machine280T1
Screw Air CompressorEAV37-71
CNC Milling MachineCNC-M4

CMMCarl Zessis1
X-ray DetectorSANDT1
Cleanliness Test EquipmentChina1
Leakage Test EquipmentChina2
Salt Spray Testing EquipmentChina1
Pneumatic Measuring InstrumentChina2
Hardness Testing MachineChina1
Color Meter MachineChina1
Thickness Testing MachineChina1
Electronic BalanceChina1
Density BalanceChina1
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If you have any questions on your die casting tooling projects or you are looking for a China aluminum die casting manufacturer, you are welcome to contact Honjenny Metal.  Our experienced engineering team consults for your die casting mold projects with skillful suggestions and solutions based on your CAD and Step drawings.



Die casting molds aid in producing aluminum and zinc die casting parts in the desired shapes and forms. Honjenny Metals is a leading manufacturer of aluminum and zinc die castings in China, producing high-quality aluminum and zinc die casting molds with a long service life.

We adhere to strict international standards, with special emphasis on the structural design and precision machining of die casting molds to ensure their durability. Our die casting mold division also assists in optimizing key die casting manufacturing processes, providing reliable die casting components to numerous industries worldwide.


The pressure casting mold is an advanced tool used in metal processing. Its main function is to form precise metal parts during the die casting process. Imagine using high pressure to inject molten metal into a specially made sturdy mold, which is the die casting mold. The design of the mold is very precise, and it can produce a variety of complex and fine shapes. This method is especially suitable for mass production, such as metal parts for automobile parts or household appliances. Because the mold is very durable, it can be used to produce a large number of identical parts, and the quality and details of each part can be maintained consistently. Simply put, the die-casting mold is like an efficient and precise "mold" for making metal parts.


Preparing a die casting mold involves several key steps:

  1. Design: Design the dimensions, shape, and details of the mold according to product requirements.
  2. Material Selection: Choose the appropriate mold material, usually a special steel that is resistant to high temperatures and pressures.
  3. Manufacturing: Use precision machining techniques to manufacture each part of the mold.
  4. Assembly and Adjustment: Assemble the parts of the mold and adjust them to ensure precise fitting.
  5. Surface Treatment: Treat the surface of the mold to improve wear resistance and corrosion resistance.
  6. Preheating and Lubrication: Preheat and lubricate the mold before use to ensure smooth metal injection.

These steps ensure that the die casting mold can accurately produce high-quality metal parts.

The process of removing castings from a die casting mold typically involves the following steps:

  1. Cooling and Solidification: First, allow the metal to fully cool and solidify within the mold. This step is crucial for ensuring the quality and dimensional accuracy of the casting.
  2. Opening the Mold: After the casting has cooled and solidified, slowly and carefully open the mold. This is usually done using mechanical arms or other automated equipment for safety and efficiency.
  3. Removing the Casting: Use special tools or mechanical devices to remove the casting from the mold. In this step, care must be taken to avoid damaging the casting or the mold.
  4. Cleaning and Inspection: After removing the casting, clean it to remove excess metal flash, and then conduct a quality inspection to ensure the casting meets design specifications.

The entire process requires precise control to ensure the quality of the casting and the long-term usability of the mold.


The lifespan of a die casting mold depends on various factors, including the material of the mold, its design, maintenance, and frequency of use. Generally, a high-quality die casting mold can produce tens of thousands to hundreds of thousands of castings under normal usage and maintenance. However, the specific lifespan also depends on factors like the type of metal being cast, the complexity of the mold, and the temperature conditions during the production process. For instance, molds used for aluminum alloy die casting usually have a longer lifespan, while those casting metals with a high melting point may wear out more quickly. Regular maintenance and proper operation can significantly extend the life of a mold.

The lifespan of a die casting mold is determined by several factors, including:

  1. Material of the Mold: High-quality materials that are resistant to high temperatures and wear can extend the life of the mold.
  2. Design: The complexity and precision of the mold's design directly affect its durability.
  3. Maintenance and Care: Regular maintenance and proper care can significantly prolong the lifespan of the mold.
  4. Frequency of Use: The more frequently the mold is used, the faster it wears out.
  5. Casting Material: Different casting metals have varying degrees of wear on the mold, for example, aluminum alloys are relatively soft and cause less wear.
  6. Temperature and Pressure in the Production Process: High temperatures and pressures can accelerate the wear of the mold.

These factors together determine the lifespan of a die casting mold, and its lifespan can be effectively extended with reasonable design and use.

  1. High wear and heat-resistant materials: For instance, using H13 or other advanced tool steels, which perform better under high temperature and pressure conditions.
  2. Efficient cooling system: Implementing advanced cooling techniques, such as optimized layout of cooling channels, to dissipate heat quickly, reduce thermal stress, and extend mold life.
  3. Precision engineering design: Precisely calculating and designing the mechanical structure of the mold to reduce wear and increase strength.
  4. Maintainability of the mold: Designing parts like internal sliders and ejector pins that are easy to maintain and replace, for quick repairs and exchanges.
  5. Multi-cavity design: Multi-cavity molds can produce more parts in a single die casting cycle, increasing production efficiency.

The moving die and fixed die in a die casting mold each serve important functions:

  1. Fixed Die (Static Mold): Typically connected to the stationary side of the die casting machine, it is responsible for forming part or all of the exterior surface of the casting. The fixed die usually contains the gate, which is the channel through which the molten metal enters the mold.
  2. Moving Die (Movable Mold): Connected to the moving side of the die casting machine, it forms the other part of the casting surface. The moving die moves at the end of the casting process to facilitate the easy removal of the casting from the mold.

During the die casting process, the moving and fixed dies work closely together to ensure that the molten metal completely fills the mold cavity under high pressure, forming precise castings. After casting, the movement of the moving die allows the casting to be removed, preparing for the next casting cycle. This design allows the die casting mold to efficiently produce complex metal parts while ensuring the quality and precision of the castings.


The heat treatment of die casting molds is a thermal processing procedure used to enhance the performance of the mold. This process involves heating the mold material to a specific temperature and then cooling it in a controlled manner. The purpose of heat treatment is to improve the mechanical properties of the mold, such as hardness, strength, and wear resistance. Common heat treatment methods include quenching and tempering. Quenching involves rapid cooling to increase hardness, while tempering is a mild heating process after quenching, designed to reduce brittleness and improve toughness. Through this process, heat treatment can significantly enhance the durability and performance of the mold, extending its lifespan, especially in the high-temperature and high-pressure environment of die casting.


  1. Enhanced Hardness and Strength: Heat treatment significantly increases the hardness and strength of the mold, making it more durable and able to withstand the high pressures and temperatures of continuous production.
  2. Improved Wear Resistance: Heat treatment enhances the wear resistance of the mold surface, reducing wear and extending the mold's lifespan.
  3. Increased Toughness: Proper heat treatment processes can also increase the toughness of the mold, reducing the risk of brittleness and fractures due to over-hardening.
  4. Improved Fatigue Resistance: Heat treatment also helps to improve the fatigue resistance of the mold, enabling it to withstand long-term repetitive stress without damage.
  5. Optimized Dimensional Stability: Controlled cooling during the heat treatment process can reduce internal stresses in the material, enhancing the dimensional stability of the mold and ensuring precise casting dimensions.

  1. Selection of Heat Treatment Process: The specific heat treatment process depends on the type of alloy used and the desired properties of the mold. Common heat treatment methods include annealing, quenching, and tempering.
  2. Preheating: Gradually preheat the mold to a specific temperature. This step is important to reduce thermal stress that might occur during the heat treatment process.
  3. Heating: Heat the mold to a higher temperature for processes like annealing or quenching. The temperature and duration depend on the material of the mold and the desired final characteristics.
  4. Soaking: Maintain the mold at a specific temperature for a period to ensure uniform temperature throughout the mold.
  5. Cooling: The cooling process should also be carefully managed. Depending on the desired material properties, methods like air cooling, oil cooling, or water cooling may be used.
  6. Tempering: For some heat treatment processes, such as quenching, the mold requires tempering after cooling. Tempering reduces the brittleness of the material and increases toughness.
  7. Cleaning and Inspection: After heat treatment, clean the surface of the mold to remove oxides and inspect for any cracks or other defects.
  8. Precise Control: Precise control of temperature and time throughout the heat treatment process is crucial to achieve the desired material properties.

The die casting mold base is a structure used in the die casting process to support and fix various parts of the mold, typically made of sturdy materials like steel or iron. It provides a stable platform to ensure precise alignment of mold components, connects and secures them to the die casting machine, and has good heat and pressure resistance. The mold base is crucial for maintaining efficiency in the die casting process and the quality of the castings.

The die casting mold cavity is the part of the die casting mold used to form the shape of the casting. It is the hollow space inside the mold where the casting material (such as molten metal) is injected and cooled to form the final product shape. The design and manufacturing of the mold cavity directly affect the quality and precision of the casting.

The manufacturing of a mold cavity typically involves the following steps:

  1. Design: First, the cavity is designed according to the required shape and size of the casting, usually using Computer-Aided Design (CAD) software.
  2. Material Selection: Appropriate mold materials are chosen, often heat-resistant, wear-resistant, and strong steel.
  3. Machining: High-precision machining techniques like CNC milling, electrical discharge machining (EDM), or grinding are used to create the specific shape and dimensions of the cavity.
  4. Polishing and Finishing: The surface of the mold cavity is polished and finished to achieve good surface quality and dimensional accuracy.
  5. Assembly and Testing: After machining, the cavity is assembled with other mold parts and tested to ensure it meets production requirements.

Since the die casting mold cavity directly determines the quality of the casting, its design and manufacturing process are highly stringent and detaile.


Maintenance and repair of die casting molds are crucial for ensuring their long-term stable operation and the production of high-quality castings. Here are some key maintenance and repair steps:

  1. Regular Inspection: Regularly check for wear and structural integrity of the mold, including components like sliders, ejector pins, cooling channels, etc.
  2. Cleaning: Clean the mold after each use to remove casting residues and lubricants. Ensure that the mold surface and cavity are kept clean.
  3. Lubrication: Regularly lubricate the moving parts of the mold to reduce wear and maintain smooth operation.
  4. Replacement of Worn Parts: Promptly replace or repair heavily worn parts, such as sliders, ejector pins, etc.
  5. Rust Prevention: Apply appropriate rust prevention, especially during prolonged downtimes or in humid environments.
  6. Heat Treatment and Surface Treatment: When necessary, perform heat treatment or surface hardening to improve durability.
  7. Precise Calibration: Ensure precise alignment of the mold parts to maintain the quality of the castings.
  8. Record Keeping and Analysis: Keep records of the mold's usage and maintenance history, and analyze this data to predict future maintenance needs.

By following these steps, the lifespan of die casting molds can be effectively extended, downtime reduced, and production efficiency and casting quality maintained.

A die casting mold typically consists of several components to ensure efficient and precise casting processes. The main parts include:

  1. Mold Cavities: The primary part that forms the shape of the casting. It consists of the moving and stationary halves, mounted on the movable and fixed sides of the die casting machine, respectively.
  2. Gating System: Includes runners, cooling channels, and gates for guiding molten metal into the mold cavities.
  3. Ejection System: Comprising ejector pins and ejector rods, used to eject the casting from the mold after it cools and solidifies.
  4. Cooling and Heating System: Used to control the temperature of the mold, ensuring the quality of the casting.
  5. Exhaust System: Helps in venting air and gases from the mold cavities to prevent porosity and bubbles.
  6. Guiding System: Ensures accurate alignment of the movable and stationary halves, typically involving guide posts and bushings.
  7. Clamping Device: Keeps the mold tightly closed during the casting process.

These components work together to ensure the precision and efficiency of the die casting process. The complexity of the mold design depends on the shape and size of the casting.



Yes, the manufacturing of die casting molds is typically a complex and expensive process, for the following reasons:

  1. High Precision Requirements: Die casting molds need to be extremely precise to ensure that the dimensions and shapes of the castings meet strict standards. This requires the use of high-precision machining technologies and equipment.
  2. Complex Design: Many die castings have complex geometric shapes, necessitating intricate design work by mold designers using advanced Computer-Aided Design (CAD) software.
  3. Durable Materials: Molds are usually made from high-quality, heat-resistant, and wear-resistant steel materials, which are inherently costly.
  4. Specialized Skills: The manufacturing of die casting molds requires highly skilled engineers and technicians, whose expertise and skills contribute to the cost.
  5. Long Manufacturing Cycles: From design to final production, creating a die casting mold can take a significant amount of time, adding to the overall cost.
  6. Maintenance and Repair Costs: Regular maintenance and occasional repairs are needed to maintain the stability and precision of the molds under high-load conditions, adding to the cost.

Therefore, despite the high cost of manufacturing die casting molds, it is justified by the need to produce high-quality, precision castings and to maintain the performance of the molds over long-term use.

When manufacturing aluminum die casting molds, choosing the right materials is crucial for ensuring the durability and efficiency of the molds. Here are some of the best materials for making aluminum die casting molds:

  1. High-Grade Tool Steel: Such as H13, A2, D2, etc. These steels have high heat resistance, good wear resistance, and sufficient toughness, suitable for withstanding the high temperatures and pressures of the die casting process.
  2. Heat-Treated Steel: Steel enhanced by heat treatment processes (like quenching and tempering) to increase the hardness and durability of the molds.
  3. Nickel-Based Alloys: In some high-demand applications, nickel-based alloys may be used due to their excellent thermal stability and corrosion resistance.
  4. Tungsten Alloys: Tungsten alloys might be a good choice in situations where extremely high wear resistance and thermal resistance are needed.
  5. Chromium-Vanadium Steel: Also a popular choice, as they offer good strength and heat resistance.

When selecting materials, the complexity of the mold design, the expected production volume, and the characteristics of the aluminum alloy must be considered. These factors determine the most suitable mold material for a specific application. Although high-quality materials may have a higher initial cost, they can improve the life and performance of the molds, reducing long-term costs.

When manufacturing zinc die casting molds, choosing the right materials is crucial to ensure the durability and efficiency of the molds. Here are some of the best material choices:

  1. High-Grade Tool Steel: Such as H13 or D2 steel, known for their excellent heat resistance, wear resistance, and strength, suitable for withstanding the high temperatures and pressures of the die casting process.
  2. Heat-Treated Steel: Steel that has been enhanced by heat treatment processes like quenching and tempering to increase the mold's hardness and durability.
  3. Chromium-Vanadium Steel: Known for good strength and heat resistance, it's a common choice for mold materials.
  4. Pre-hardened Steel: Pre-hardened mold steels can be used directly without additional heat treatment, saving time and cost.
  5. Aluminum Alloy: In applications that are less complex or have lower production volumes, aluminum alloy molds can be considered.

When selecting mold materials, the characteristics of zinc alloy, the complexity of the mold design, and the expected production volume should be taken into account. Although high-quality mold materials may have a higher initial cost, they can enhance the lifespan and performance of the molds, thereby reducing long-term costs.

Some metal casting processes that utilize die casting tooling include:

  1. Die Casting: This is the most common process using die casting molds, suitable for producing high-precision, high-quality parts from non-ferrous metals like aluminum, zinc, and copper alloys.
  2. Low-Pressure Casting: Mainly used for aluminum and magnesium alloys, it involves injecting molten metal into the mold under lower pressure.
  3. Hot Chamber Die Casting: Suitable for low melting point metals like zinc, magnesium, and certain aluminum alloys, where the molten metal is stored in a chamber that is part of the machine itself.
  4. Cold Chamber Die Casting: Used for higher melting point metals like aluminum and copper alloys, where the molten metal is heated in a furnace separate from the machine.
  5. Vacuum Casting: Particularly effective in reducing porosity and improving casting quality, it involves casting in a vacuum environment to minimize gas entrapment.

All these processes rely on precision die casting molds to produce castings with accurate dimensions and smooth surfaces.

The selection of die casting mold materials needs to consider several factors, including:

  1. Type of Die Casting Metal: Different metals have different requirements for mold materials. For instance, aluminum and magnesium alloys, having lower melting points, don't require as high heat resistance in mold materials as copper alloys do.
  2. Mold Lifespan: The number of parts the mold is expected to produce needs to be considered. High-volume production typically requires more durable, wear-resistant materials.
  3. Operating Temperature of the Mold: Different die casting materials perform differently at various operating temperatures, so it's essential to choose a material that can withstand the highest temperatures encountered during the casting process.
  4. Machinability of the Mold: The mold material needs to be easily machined into complex shapes and details.
  5. Corrosion Resistance: Since corrosive substances may be involved in the die casting process, the mold material should have a certain level of corrosion resistance.
  6. Economic Factors: Cost is an important consideration. High-performance materials may be more expensive, but they might offer better value due to their longer lifespan.
  7. Heat Treatment Properties: The performance of mold materials during heat treatment, such as hardness, toughness, and stability, is also an important consideration.
  8. Mechanical Properties: Including hardness, toughness, strength, etc., these directly affect the durability and stability of the mold.

In summary, choosing die casting mold materials is a process that involves considering multiple factors and should be determined based on specific production needs and conditions.

Yes, die casting molds can produce some defects during the production process. These defects mainly include:

  1. Porosity and Shrinkage: These are cavities caused by trapped gas inside the mold or material shrinkage during cooling. To prevent this, optimizing the design of the gating system and controlling the appropriate pouring temperature and pressure can reduce air entrapment in the castings.
  2. Cold Shuts: This occurs when the liquid metal does not fully merge inside the mold, forming cold shuts. This can be prevented by increasing the pouring temperature of the metal and the temperature of the mold.
  3. Warping or Distortion: Uneven cooling rates during the cooling process can cause the casting to warp or distort. To prevent this, it's essential to ensure uniform temperature throughout the cooling process of the casting.
  4. Hot Cracks: These are cracks caused by uneven contraction of the metal and uneven fixation of the mold. Hot cracks can be prevented by optimizing mold design and controlling the cooling rate.
  5. Sticking: This occurs when the casting and the mold surface adhere too much and are difficult to separate. Applying an appropriate amount of release agent or improving the surface treatment of the mold can reduce sticking.

The key to preventing these defects lies in meticulous planning and control during the design and production process, including mold design, material selection, and optimization of processing parameters.

Yes, die casting molds do affect the quality of the metal parts produced. The design, material, and manufacturing process of the mold significantly impact the dimensional accuracy, surface finish, and mechanical properties of the final product. If the quality of the mold is poor, it may lead to defects in the metal parts, such as porosity, cracks, or inaccuracies in size. Therefore, high-quality die casting molds are crucial for producing high-quality metal parts.

Designing and manufacturing high-quality die casting molds involves following several key steps:

Material Selection: Choosing the right mold material is crucial. Typically, alloy steel that is heat-resistant, wear-resistant, and has good mechanical strength is used.

Precision Design: Utilize advanced Computer-Aided Design (CAD) software for mold design to ensure that the design meets production requirements and accurately forms the parts.

Mold Processing and Assembly: Employ high-precision processing techniques, such as CNC machining, to ensure the mold's dimensions and shapes are accurate. Moreover, the various components of the mold need to be precisely assembled and aligned.

Surface Treatment and Heat Treatment: Proper surface and heat treatment of the mold are conducted to enhance its durability and performance. This includes processes like hardening, carburizing, or plating.

Testing and Adjustment: Before production, conduct mold testing to check for any defects. Make adjustments as necessary to ensure it can produce high-quality parts.

Maintenance and Monitoring: Regularly maintain and inspect the mold to maintain its optimal performance. Implement quality control measures during production to ensure consistent quality of parts.

By following these steps, molds capable of producing high-quality die-cast parts can be designed and manufactured.


In the manufacturing process of die casting molds, achieving the correct draft angle is extremely important for several reasons:

  1. Preventing Part Sticking: An appropriate draft angle helps prevent the casting from sticking to the mold. If the draft angle is insufficient, the casting may adhere to the mold surface, making removal difficult and potentially damaging the part or mold.
  2. Ensuring Part Quality: The correct draft angle helps maintain the dimensional accuracy and surface smoothness of the casting. This is crucial for producing high-quality parts.
  3. Improving Production Efficiency: A suitable draft angle can reduce downtime and mold maintenance in production, thus enhancing overall production efficiency.
  4. Extending Mold Life: The right draft angle reduces the friction and wear between the mold and the casting, thereby extending the mold's lifespan.
  5. Facilitating Casting Removal: An appropriate draft angle makes it easier to remove the casting from the mold, reducing mechanical stress on the casting and lowering the risk of defects.

Therefore, to ensure casting quality, efficiency, and mold durability, obtaining the correct draft angle is a key consideration in the manufacture of die casting molds.


Die casting mold flow analysis is a computer simulation technique used to predict and optimize the behavior of metal flow and solidification in the die casting process. This analysis is crucial for the die casting process for several reasons:

  1. Predicting Metal Flow: Mold flow analysis can accurately predict the path of metal flow within the mold, helping to identify potential flow problems, such as air entrapment or incomplete filling.
  2. Optimizing Mold Design: Through simulation analysis, engineers can optimize mold design, improve gating systems, ensure casting quality, and reduce material waste.
  3. Improving Production Efficiency: Mold flow analysis helps reduce trial and error, speeding up the product development cycle and enhancing production efficiency.
  4. Ensuring Casting Quality: This analysis can predict and reduce defects in the casting, such as porosity, shrinkage cavities, and cold shuts, thereby improving the overall quality of the casting.
  5. Cost Savings: By optimizing casting parameters and reducing defects, mold flow analysis contributes to lowering production costs and improving economic efficiency.


Using flow analysis and computer simulation can indeed achieve optimal mold design. These technologies provide important insights and optimization tools for the mold design and manufacturing process. Specifically:

  1. Accurate Prediction: Flow analysis can accurately predict the flow of material in the mold, helping to identify potential issues such as bubble formation, material shortage, or excess.
  2. Optimizing Mold Design: Through computer simulation, different design scenarios can be tested before production to find the most suitable mold design for production needs.
  3. Shortening Development Cycle: These technologies reduce the need for physical trials, thereby speeding up the process from design to production.
  4. Reducing Costs and Improving Efficiency: Optimized mold design can reduce raw material waste, improve production efficiency, and lower production costs.
  5. Improving Product Quality: By predicting and optimizing the quality of castings, computer simulation helps to reduce defects, enhancing the consistency and quality of the final product.

To ensure the production of high-precision aluminum die casting molds, several key steps can be taken, and CNC (Computer Numerical Control) machines play a very important role in this process:

  1. Accurate Design and Engineering Planning: Use advanced Computer-Aided Design (CAD) software to create precise mold designs. This helps ensure that the dimensions and shapes of the molds meet strict tolerance requirements.
  2. Selection of High-Quality Materials: Choose high-quality aluminum materials and other alloying elements that have good casting properties and mechanical strength.
  3. Machining with CNC Machines: CNC machines provide highly precise machining capabilities, making them ideal for manufacturing complex and fine mold components. The precise control offered by CNC machines helps achieve accurate dimensions and details in the mold.
  4. Strict Quality Control: Implement rigorous quality control during the production process, including inspection of materials, machining processes, and the final product, to ensure the accuracy and quality of the mold.
  5. Regular Maintenance and Calibration: Regularly maintain and calibrate CNC machines to ensure they are always in optimal working condition, thereby maintaining the precision of mold machining.


The reasons for discarding defective die casting molds before use include:

  1. Ensuring Product Quality: Castings produced using defective molds often have flaws such as inaccurate dimensions, rough surfaces, or structural weaknesses. This directly impacts the quality of the final product.
  2. Avoiding Safety Risks: Faulty molds may crack or get damaged during the casting process, which can harm equipment and pose safety risks to operators.
  3. Reducing Economic Losses: Continuing to use flawed molds can lead to more production waste, increasing raw material and production costs, thus causing economic losses.
  4. Improving Production Efficiency: Defective molds can cause production interruptions, affecting production efficiency. Discarding and replacing them promptly can minimize downtime.
  5. Maintaining Brand Reputation: Low-quality products produced with faulty molds can damage a company's brand and market reputation.