Whether you are an engineer, a procurement specialist, or a project manager, working with a reliable casting partner is a key step to ensure your project’s success.
We will explain the full process to you in detail, from project start to product delivery. We will break down step by step the materials you need to prepare when working with QD, the services we will provide, and the quality control checkpoints at each stage.
Step 1: Consultation and Quotation
At the initial stage of project launch, providing clear and complete information is the foundation for ensuring the smooth progress of subsequent processes. The more detailed the information you provide, the more accurate our quotation and technical suggestions will be.
Usually, you need to prepare the following:
| Item | Description | Remarks |
| Clear drawings or 3D models | It is recommended to provide common formats. such as STEP, IGES, and PARASOLID. | If there are special markings (such as tolerances, key dimensions), please indicate them. |
| Material requirements | For example: stainless steel 304/316 high-temperature alloy aluminum alloy, etc. | Can refer to standards such as ASTM, GB, ISO. |
| Annual demand | Estimate the annual usage to facilitate us in optimizing production and quotation strategies. | We can accept both small and large batches. |
| Surface treatment standards | Such as sandblasting, electroplating, polishing, spraying, etc. | Can recommend according to application scenarios. |
| Other special requirements | Such as non-destructive testing, heat treatment, material reports, etc. | Stating in advance can avoid subsequent changes. |
If you are not familiar with materials or processes, just provide the purpose and working environment of the part. QD engineers will recommend the most suitable solution for you.
Step 2: Design and Engineering Review
After receiving your materials, QD does not rush into production. We will start the design and engineering review process. This is a key step that many customers recognize us for.
Our engineering team will conduct Design for Manufacturability analysis on your parts based on their rich investment casting experience. They will also put forward optimization suggestions.
For example:
- Wall thickness optimization: Check for uneven wall thickness or areas that are too thick or too thin. Put forward modification suggestions to avoid casting defects (such as shrinkage holes, cracks) and ensure the structural integrity of the part.
- Draft angle and parting line: Set the draft angle properly to ensure smooth mold release. Optimize the position of the parting line to minimize subsequent cleaning work and improve appearance.
- Structure simplification: On the premise of meeting functional requirements, suggest simplifying unnecessary complex structures. This can significantly reduce mold difficulty and manufacturing costs.
- Material and process matching: Based on the service conditions and performance requirements of the part, recommend the most economical material grade and corresponding heat treatment process.
Example: A medical device customer had a junction between a thin wall and a thick wall in their original design. This junction was prone to shrinkage holes. We suggested they adjust the transition area slightly and add cooling compensation in the mold design. Finally, the part qualification rate increased to 98% and the cost decreased by 12%.
Step 3: Mold Manufacturing and Sample Confirmation
After the design and process plan are confirmed, we will start mold manufacturing. QD uses high-precision CNC machining and EDM process to make mold sets, ensuring stable mold dimensions and long service life.
The key checkpoints of this stage include:
- Mold design drawing confirmation: Before processing, we will provide detailed mold design drawings (including gating systems, core-pulling mechanisms, etc.) for your review and confirmation. This ensures the mold structure meets your expectations.
- First sample production: After the mold is initially completed, we will use wax or rapid soft mold process to produce a small number of first samples.
- Comprehensive sample inspection and confirmation: You will verify the sample’s dimensions, appearance, and even assembly. At the same time, we will also provide a First Article Inspection (FAI) report to ensure data transparency. Only after both parties confirm in writing that the sample is fully qualified will we enter the mass production stage. This fundamentally avoids the risk of mass errors.
Step 4: Production and Comprehensive Quality Inspection
After entering the production stage, QD will strictly implement the established process parameters and set up quality control points in multiple links:
| Inspection Category | Inspection Method | Standard Basis | Control Purpose |
| Dimensional Inspection | Coordinate measuring machine, optical projector, customized inspection tool | Drawing requirements, ISO 8062 – GCT | Ensure part assembly and function realization |
| Chemical Composition | Direct reading spectrometer | ASTM E1251, GB/T 223 | Ensure the material grade meets specifications |
| Mechanical Properties | Universal testing machine, impact testing machine, hardness tester | ASTM A370, GB/T 228 | Verify key indicators such as material strength and toughness |
| Surface Defects | Visual inspection (AQL sampling), fluorescent penetrant testing | ASTM E165, ISO 3452 | Detect surface cracks, holes, etc. |
| Internal Defects | X ray real time imaging, ultrasonic flaw detection | ASTM E94, ASTM E114 | Detect internal shrinkage cavities, inclusions and other defects |
All our testing equipment is calibrated regularly, and testing personnel work with valid certificates. Each batch of parts has a unique traceability number. This ensures that each batch of parts is traceable and the data is true and reliable.
Step 5: On-time Delivery and After-sales Service
We fully understand that on-time delivery is crucial to your project schedule. QD uses an ERP system to track order status. Before shipment, we confirm packaging details with you and provide detailed logistics tracking information.
Even after delivery, we still provide comprehensive after-sales service:
- Document support: We provide a complete quality document package with the goods, including material certificates, inspection reports, qualification certificates, etc.
- Rapid response mechanism: If you find any problems during receipt or use, we promise to give a substantive response within 48 hours and immediately start the problem investigation and resolution process.
- Long-term cooperation support: For long-term cooperative customers, we provide regular production review meetings. We analyze quality data together, continuously discuss the possibility of process optimization, and help you continuously reduce costs and improve efficiency.
Contact Us
Is your next project in planning? Whether you are in the concept stage or have complete drawings, the QD team is ready to be your most reliable manufacturing partner.
FAQ
1. How long does it usually take from inquiry to receiving samples?
It is usually 3 to 5 weeks. The exact time depends on part complexity and mold difficulty. We will provide a detailed schedule after receiving your materials.
2. What file formats do you support?
We support mainstream 3D formats such as STEP, IGES, X_T and SLDPRT, as well as PDF and DWG drawing files.
3. What is the minimum order quantity?
We support production from prototypes to mass production, and the minimum order can be as low as 10 pieces.
4. Do you provide material certificates and inspection reports?
Yes. Each batch of parts will come with material certificates and first article inspection reports. According to your requirements, we can also provide more comprehensive performance test reports and non destructive testing reports.
5. How to handle it if there are design changes?
Design changes require re-conducting engineering review. If the mold has not been made yet, modifications usually have no extra cost. If it has been made, we will evaluate the modification scope and provide suggestions.
6. Do you have industry certifications?
We have passed the ISO 9001:2015 quality management system certification. For industries with special requirements such as aerospace and medical care, we have corresponding process control capabilities and testing methods. And according to customer requirements, we can produce in accordance with the standards of systems such as AS9100 or ISO 13485. We will also fully cooperate with customers in third party audits.