How Does Our Die-Cast Enclosure Service Work?

In TOPS Precision, our services of die-cast enclosures have a lean and quality-driven procedure:

Requirement Analysis

At the TOPS Precision project, all die-cast enclosure begins with a detailed requirement analysis. Clients collaborate with our engineering team to learn the application, dimensional requirements, environmental factors, material requirements, and anticipated quantity of production. This initial analysis ensures that the design is functional and attains performance requirements as well as cost objectives.

Design & Prototyping

When the requirements are established, our designers create the correct 3D representation using the state-of-the-art CAD program. Such computer models allow us to refine wall thickness, structural integrity, heat dissipation, and assembly fit. We subsequently develop quick prototypes to identify issues at an early stage and to ensure that the enclosure looks and works as we want it to before large-scale production.

Tooling & Mold Making

Once the design is approved, TOPS Precision designs high-precision die-casting molding using CNC machining and EDM methods. These molds are designed to be durable, precise in terms of size, and reproducible in terms of repeats, so as to make complicated enclosure shapes with strict tolerances. Mold design is also effective at reducing waste of materials and enhancing production.

Die Casting Production

In die casting, the molten metal is pressurized to fill the disposable molds. The outcome is a smooth and strong structure with a smooth surface and an even quality enclosure. Defects such as porosity are also prevented by our controlled environment and competent operators to provide high-performance parts that can be depended upon.

Finishing & Inspection

Each enclosure is cast, trimmed, CNC machined, finished in surface, and coated where necessary. Then, each of the parts undergoes rigid quality checks, such as dimensional and visual checks, in order to meet ISO 9001:2015 rules. Only those parts that pass our specifications are shipped.

Advanced Die-cast Enclosure Techniques

Our enclosures are made with high die-casting methods to enhance performance and quality:

High-Pressure Die Casting

TOPS Precision utilizes high-pressure die casting as a central method to make enclosures with complicated shapes and high quality of surface. The high-pressure injection of molten metal into precision molds creates high-quality mechanical strength, fine detail, and uniform wall thickness. It is perfect in high volume production and rigorous industrial use.

Vacuum Die Casting

Vacuum die casting is used when structural integrity is required, and fewer internal defects are needed. The method minimises porosity by removing the trapped air in the mold cavity before injection. This leads to enhanced mechanical performance, surface quality, and reliability, particularly in enclosures of high-performance or safety-critical nature.

Two-Stage Die Casting

The Two-stage die casting provides a possibility to manufacture a higher level of enclosure designs that require a more sturdy body or multi-material incorporation. It offers more control over the flow of metal and its solidification and provides enhanced internal structures and dimensional stability. It is effective with elaborate enclosures, reinforced enclosure or special functional areas.

Accurate Casting After Casting

Die casting is followed by precision CNC machining to put a tight tolerance on the parts and functional features. This post-casting ensures accurate hole location, planar surfaces, and critical interface dimensions. It enables die-cast enclosures to fit snugly with internal components and mating parts and ensure that they comply with rigid engineering requirements.