Introduction
In today’s manufacturing industry, product quality, cost, and delivery, QCD, are critical factors that determine a company’s competitiveness. Aluminum die casting products, in particular, are in high demand across a wide range of fields such as automobiles, home appliances, and industrial machinery, due to their lightweight, high strength, and recyclability. However, merely supplying molded parts is no longer sufficient to meet market demands. The final performance and functionality of a product are determined by “secondary processing“ after die casting. The quality and efficiency of this secondary processing significantly influence the added value of the product.
This article delves into the importance of secondary processing in aluminum die casting products, explaining how it can enhance product value and strengthen market competitiveness. We will also introduce how Daiwa Aluminum Vietnam, based in Vietnam, can provide high-value-added solutions to Japanese manufacturers through advanced secondary processing technology and an integrated production system.
The Importance of Secondary Processing in Aluminum Die Casting
While aluminum die casting products offer the significant advantage of being able to form complex shapes in a single process, they also face challenges inherent to casting. To overcome these challenges and meet the strict functionality and quality standards required for products, advanced secondary processing is indispensable.
Ensuring Dimensional Accuracy and Geometric Tolerances through Precision Machining
Die casting products can experience dimensional errors from design values due to slight gaps between the mold and the product during casting, or due to cooling shrinkage. Especially for products that are assembled with multiple parts or have sliding components, precise dimensional accuracy down to a few microns is required. For example, automotive parts often demand strict dimensional tolerances of ±0.05mm, and sometimes even ±0.02mm. Through cutting, drilling, tapping, and milling using CNC, Computer Numerical Control, machining centers, these strict geometric tolerances, such as roundness, flatness, and perpendicularity, can be achieved, dramatically improving product functionality and reliability. Daiwa Aluminum Vietnam has introduced numerous state-of-the-art CNC machining centers to handle even the most intricate processing.
Improving Corrosion Resistance, Wear Resistance, and Design Aesthetics through Surface Treatment
Aluminum die casting products, if left untreated, can be prone to surface oxidation, posing challenges in terms of corrosion resistance and wear resistance. Furthermore, the external appearance of a product directly impacts brand image and customer satisfaction. By applying various surface treatment technologies, these issues can be resolved, enhancing the product’s lifespan and appeal.
- Anodizing, Anodic Oxidation Treatment,: Forms a robust oxide film on the aluminum surface, improving corrosion resistance, wear resistance, and electrical insulation. Film thickness typically ranges from 5μm to 30μm, adjusted according to application. Colored anodizing also allows for diverse color expressions.
- Painting: Powder coating or liquid painting enhances corrosion resistance, weather resistance, and chemical resistance, while also providing an attractive appearance. Widely adopted for automotive parts and home appliances.
- Plating: Nickel plating, chrome plating, etc., improve hardness, wear resistance, and electrical conductivity. Particularly used for precision instrument components.
- Chemical Conversion Treatment: Includes chromate treatment and non-chromate treatment, used as a primer for painting or for temporary rust prevention.
The optimal surface treatment is selected based on the product’s application and environmental conditions, significantly increasing the product’s added value. Daiwa Aluminum Vietnam provides these surface treatment technologies in-house or through partner factories, supplying products under consistent quality control.
Improving Mechanical Properties through Heat Treatment
For specific applications, aluminum die casting products may require additional strength or hardness. Heat treatment is a technology that improves mechanical properties by altering the material’s crystal structure. For example, T5 treatment, artificial aging, or T6 treatment, solution heat treatment + artificial aging, can increase tensile strength by 10% to 30%. This allows for the provision of products that can withstand use in more severe environments.
Source: About Heat Treatment for Die Casting
Quality Stabilization and Cost Reduction through In-house Assembly Processes
For products composed of multiple parts, integrating the entire process from die casting part manufacturing to assembly significantly contributes to quality stabilization and total cost reduction. It reduces the risk of dimensional errors between parts and assembly defects, ensuring the quality of the final product. Furthermore, it eliminates the hassle of ordering from multiple suppliers, as well as transportation, storage, and intermediate inspection costs for parts. Daiwa Aluminum Vietnam actively promotes such in-house assembly processes, supporting the optimization of our customers’ entire supply chain.
Daiwa Aluminum Vietnam’s Advanced Secondary Processing Technology
Daiwa Aluminum Vietnam has established advanced secondary processing technology and an integrated production system in Vietnam to provide high-quality and cost-efficient aluminum die casting products that meet the demands of Japanese manufacturers.
High-Precision Machining Capability with State-of-the-Art CNC Machining Centers
To meet Japan’s stringent quality standards, our company possesses over 30 state-of-the-art CNC machining centers. This enables precision machining down to micron levels, accommodating demanding dimensional tolerances, e.g., ±0.02mm, and surface roughness, e.g., Ra 0.8, Ra 0.4,. We have extensive experience, particularly in fields requiring high reliability, such as automotive parts and medical device components. In the machining process, we have introduced an automatic measurement system to ensure quality through near 100% inspection. Our goal is to keep the defect rate at a ppm level, Parts Per Million,.
Diverse Surface Treatment Technologies and Quality Control System
We offer various surface treatment technologies, including anodizing, painting, plating, and chemical conversion treatment, either in-house or in collaboration with carefully selected partner factories. Particularly for anodizing, we strictly control the uniformity and adhesion of the film thickness, ensuring quality compliant with JIS standards. Specialized inspectors conduct quality checks at each stage, establishing a system that reliably meets customer requirements.
Fusion of Skilled Manual Work and Automation
Leveraging Vietnam’s abundant workforce, our strength also lies in manual deburring, polishing, and finishing by skilled workers. This allows us to handle complex shapes that are difficult for machine processing, as well as products requiring high aesthetic appeal. Simultaneously, for repetitive tasks and mass-produced items, we introduce robots and automated machines to standardize quality and improve production efficiency. This fusion of skilled craftsmanship and cutting-edge automation technology is a key strength of Daiwa Aluminum Vietnam.
Quality Assurance and Lead Time Reduction through Integrated Production System
Daiwa Aluminum Vietnam has established a system that can handle everything from mold design and manufacturing, die casting, secondary processing, machining, surface treatment, assembly, inspection, packaging, and shipping, all in an integrated manner. This integrated production system ensures thorough quality control at each stage and guarantees traceability from component supply to the final product. Furthermore, by managing all processes in-house or under our control, without involving multiple suppliers, we can reduce lead times by an average of 20%, contributing to lower inventory risks for customers and faster time-to-market. This significantly simplifies our customers’ procurement processes and improves overall supply chain efficiency.
Cost Competitiveness Leveraging Vietnam’s Labor Cost Advantage
Vietnam is attracting attention as a manufacturing hub within the ASEAN region, thanks to its relatively stable political situation and a diligent, young workforce. While minimum wages vary by region in 2023, they range from approximately 180 to 220 USD per month, about 27,000 to 33,000 JPY, offering a significant advantage compared to labor costs in Japan.
Source: Current State and Outlook of Vietnam’s Manufacturing Industry.
Daiwa Aluminum Vietnam maximizes this labor cost advantage while maintaining Japanese quality standards, providing solutions that enable customers to achieve an average cost reduction of over 15%.
Key Data of Daiwa Aluminum Vietnam
| Item | Value | Remarks |
|---|---|---|
| Number of CNC Machining Centers Owned | Over 30 units | Many state-of-the-art machines introduced |
| Dimensional Tolerance for Main Products | ±0.02mm | Supports parts requiring high precision |
| Surface Roughness Capability | Up to Ra 0.4 | Achieves high-quality surface finish |
| Lead Time Reduction Achievement | Average 20% | Effect of integrated production system |
| Cost Reduction Achievement | Average over 15% | Utilizing Vietnam’s production advantage |
| Quality Target | ppm level | Minimizing defect rate to the extreme |
Source: Daiwa Aluminum Vietnam internal data
Customer Value and Market Competitiveness Brought by Advanced Secondary Processing
Daiwa Aluminum Vietnam’s advanced secondary processing technology brings significant added value to our customers’ products and contributes to enhancing their market competitiveness.
Product Functionality Improvement and Differentiation
Precision machining and diverse surface treatments improve product functionality, durability, and design aesthetics. This enables customers to differentiate themselves from competitors and introduce higher-performance, more attractive products to the market. For example, with the electrification of automobiles, EVs, battery cases and motor housings require not only lightweighting but also high heat dissipation and electromagnetic shielding. These are achieved through precision machining and special surface treatments after die casting.
Supply Chain Simplification and Risk Reduction
Through an integrated production system, customers can avoid the hassle of negotiating with multiple suppliers, significantly simplifying their procurement process. Consolidating suppliers to Daiwa Aluminum Vietnam can potentially reduce overall supply chain costs by 5% to 10%. Furthermore, with a single point of contact, communication costs are reduced, and accountability for quality issues becomes clear. This mitigates supply chain risks and ensures stable component supply.
Total Cost Optimization, Reduction of Procurement, Processing, Inspection, and Logistics Costs,
Production in Vietnam not only offers the aforementioned labor cost advantage but also contributes to optimizing logistics costs. For product supply to the Asian region, transportation from Vietnam can be geographically advantageous. Moreover, integrated production reduces costs associated with intermediate transportation, storage, and inspection, optimizing the total cost of the product. This enables customers to strengthen the price competitiveness of their final products and improve profit margins.
Reduction of Quality Issues and Improvement of Customer Satisfaction
A rigorous quality control and inspection system can significantly reduce initial product defects and quality claims. For example, our track record shows an average annual reduction of 15% in quality claim rates. This allows customers to enhance product reliability and improve evaluations and satisfaction from end-customers. High-quality products also directly contribute to an improved brand image.
Conclusion
To maximize the value of aluminum die casting products, advanced secondary processing technology is indispensable. By not merely supplying parts but also integrating precision machining, diverse surface treatments, heat treatment, and assembly, product functionality, quality, and cost competitiveness can be dramatically improved.
Daiwa Aluminum Vietnam offers optimal solutions to Japanese manufacturers by combining state-of-the-art equipment, skilled technicians, and Vietnam’s production advantages. We promise to provide high-quality aluminum die casting products that meet our customers’ stringent requirements, cost-effectively and with short lead times, by managing all processes from mold design to final product shipment in-house.
For Japanese manufacturing executives and procurement managers considering overseas sourcing or supply chain optimization, Daiwa Aluminum Vietnam will be a reliable partner. We are committed to continuous technological development and customer support to ensure that our customers’ products achieve high added value and establish strong market competitiveness. Please do not hesitate to contact Daiwa Aluminum Vietnam.