High-volume aluminum (A380, ADC12) and zinc (Zamak 3, 5) die casting. We deliver precision components meeting NADCA standards, ensuring tight tolerances and superior surface finishes that minimize secondary machining.
Cold & Hot Chamber machines from 150 to 1,200 Tons | ISO 9001:2015 & IATF 16949 Compliant.
High-precision metal parts with integrated post-processing and full-BOM support — direct from factory floor.
Direct factory production in Vietnam. Engineered for high-integrity components with controlled porosity and superior metal purity.
Lead Time
Sample parts as fast as 10–15 days.
Premium Tooling
Precision-machined hardened H13 tool steel for high-volume durability.
Tolerances
±0.1 mm / 25 mm raw casting. ±0.05 mm post-CNC features.
Rapid Prototyping
Integrated SLA/SLS wax patterns for accelerated tool validation.
3D Scanning
Rapid design validation and reverse engineering.
VNcontx operates high-precision CNC machining centers configured specifically for post-die-casting operations. We eliminate parting lines, achieve critical tolerances to GD&T ±0.005mm, and machine complex features that cannot be cast. Our integrated Zero-Defect Protocol ensures seamless transition from mold to final finished component.
| MaterialsAl, Zn, Mg Die Cast | Primary StandardNADCA · ISO 9001:2015 | Inspection MethodsVisual · CMM · XRF | Record RetentionMinimum 5 Years |
| Item | Description | Status |
|---|---|---|
| Document Purpose | Define cosmetic acceptance and rejection criteria for all VNcontx die cast parts | Mandatory |
| Surface Zone Classification | Categorize part surfaces into Zone A / B / C based on visibility and functional criticality | Mandatory |
| Surface Roughness | Specify Ra and Rz values per zone; measured with contact profilometer per ISO 4288 | Mandatory |
| Visual Inspection Protocol | Standardized D65 lighting, viewing distance, angle of observation, and AQL sampling levels | Mandatory |
| Rejection Criteria | Defined defect list with quantified acceptance limits per surface zone | Mandatory |
| Golden Sample / Limit Sample | Customer-approved reference sample used as visual inspection benchmark — replaced every 6 months | Recommended |
| Zone C Exclusion | Fully concealed surfaces — functional inspection only; no cosmetic requirement applies | Reference |
| Zone | Classification | Location Description | Inspection Level | Typical Examples |
|---|---|---|---|---|
| Zone A | Critical / Cosmetic | Directly visible under normal use at ≤ 500 mm viewing distance | Most Stringent | Front face, outer housing, user-contact surfaces |
| Zone B | Semi-Critical | Visible at certain angles or during assembly/disassembly; not the primary view | Moderate | Side walls, rear panels, inner cover surfaces |
| Zone C | Non-Cosmetic | Not visible during normal product operation; fully concealed or internal | Least Stringent | Enclosed cavities, hidden mating surfaces, blind bores |
| Surface Type | Default Zone | Notes |
|---|---|---|
| Mating / Faying Surfaces | A or B | Per drawing callout; dimensional tolerance takes precedence |
| Threaded Features | B | Thread gauge inspection required; Zone A cosmetic criteria not applicable |
| Post-Finish Surfaces (anodize, powder coat) | A | Inspect after finishing; coating may conceal minor casting imperfections |
| Ejector Pin Marks | C (preferred) | If Zone A/B location: pre-approval required; flash ≤ 0.1 mm |
| Parting Line Region | B / C | Flash ≤ 0.2 mm Zone B; ≤ 0.3 mm Zone C; not acceptable Zone A |
| Defect | Definition | Zone A | Zone B | Zone C |
|---|---|---|---|---|
| Scratch | Visible linear mark or abrasion on surface | Not Acceptable | L ≤ 5 mm; not perceptible by fingernail | Acceptable |
| Dent / Ding | Localized material impression from mechanical impact | Not Acceptable | ≤ 0.3 mm in any dimension | ≤ 0.5 mm |
| Porosity | Sub-surface or surface voids from trapped gas during solidification | Reject if Φ > 0.5 mm | ≤ 1.0 mm; ≤ 3 pits/dm² | ≤ 2.0 mm; ≤ 5/dm² |
| Cold Shut | Junction of two metal streams that met below fusion temperature | Not Acceptable | Not Acceptable | Acceptable if no structural impact |
| Flow Mark | Surface pattern resulting from metal flow dynamics during injection | Not Acceptable | Faint; not visually dominant | Acceptable |
| Flash | Thin metal fin at parting line or ejector pin locations | 0 mm | ≤ 0.1 mm | ≤ 0.2 mm |
| Sink Mark | Surface depression caused by solidification shrinkage | Not Acceptable | Depth ≤ 0.05 mm | ≤ 0.1 mm |
| Gouge | Deep imperfection penetrating surface with raised or torn edges | Not Acceptable | Not Acceptable | Not Acceptable |
| Discoloration | Inconsistent or non-uniform coloration across the surface | ΔE < 2.0 | ΔE < 4.0 | ΔE < 8.0 |
| Blister | Sub-surface gas pocket causing a surface bulge | Not Acceptable | Not Acceptable | Acceptable if no functional impact |
| Burr | Sharp raised edge remaining after casting or secondary machining | Not Acceptable | Not Acceptable | Not Acceptable |
| Tool Mark | Visible mark imparted by clamping or cutting tooling | Not Acceptable | Not perceptible with thumbnail | Acceptable |
| Zone / Surface Type | Ra max (µm) | Rz max (µm) | Measurement Method | Min. Sample Points |
|---|---|---|---|---|
| Zone A — Primary Cosmetic | 1.6 | 10 | Contact profilometer | 5 pts/area |
| Zone B — Secondary Cosmetic | 3.2 | 20 | Contact profilometer | 3 pts/area |
| Zone C — Non-Cosmetic | 6.3 | 40 | Visual or profilometer | As required |
| Mating / Sealing Surfaces | 1.6 | 10 | CMM + profilometer | 5 pts/area |
| Threaded Features | 3.2 | 16 | Thread gauge + profilometer | Per ISO 965 |
| After Anodizing | 1.6 | 10 | Measure post-finish | 5 pts/area |
| After Powder Coating | 3.2 | 20 | Measure post-finish | 3 pts/area |
| Parameter | Requirement | Notes |
|---|---|---|
| Light Source | D65 / 6500 K, CRI ≥ 90 | Standard fluorescent lamps are not acceptable |
| Illuminance | 1000 – 2000 lux at part surface | Verify with calibrated lux meter before each production shift |
| Viewing Distance | 450 – 550 mm | Inspector’s eye to Zone A/B surface |
| Viewing Angle | 45° ± 10° from surface normal | Rotate part to inspect all critical angles |
| Min. Inspection Time | ≥ 30 sec per Zone A per part | Max 4 consecutive hours per inspector without break |
| Reference Sample | Customer-approved Golden Sample | Replace every 6 months or upon customer request |
| AQL — Zone A | AQL 0.65, Level II (ANSI/ASQ Z1.4) | 100% inspection mandatory for pilot lots and PPAP submissions |
| AQL — Zone B | AQL 1.5, Level II | — |
| AQL — Zone C | AQL 4.0, Level I | Functional inspection takes priority over cosmetic |
| Inspector Qualification | Trained in die casting defect recognition | Vision acuity check required every 6 months |
| Condition | Disposition | Required Action |
|---|---|---|
| All Zone A, B, C criteria met | PASS | Pack per applicable work instruction; release to shipping |
| Any Zone A criterion violated | REJECT | Quarantine lot; issue NCR; root cause analysis within 24 hours |
| Zone B exceeds limit; Zone A passes | MRB | Material Review Board: rework / scrap / use-as-is with approved deviation |
| Zone C exceeds limit; A & B pass | MRB | Assess functional impact; disposition decided case-by-case |
| Entire lot fails AQL sampling plan | REJECT LOT | 100% sort or return to manufacturing |
| Repairable defect (deburr, polish) | REWORK | Rework per approved work instruction; 100% re-inspection required after rework |
| Condition not listed in defect table | CONSULT | Escalate to VNcontx Quality Engineering and customer before disposition |
| Standard | Full Title | Application |
|---|---|---|
| NADCA Product Spec | North American Die Casting Association — Engineering & Design Standards | All Al, Zn, Mg die cast products |
| ISO 9001:2015 | Quality Management Systems — Requirements | VNcontx QMS framework |
| ANSI/ASQ Z1.4 | Sampling Procedures and Tables for Inspection by Attributes | AQL sampling plans |
| ISO 4288 / ASME B46.1 | Surface Texture — Profile Method; Surface Texture Standard | Ra, Rz measurement methodology |
| CIE D65 / ISO 3664 | Colorimetry — D65 Standard Illuminant; Viewing Conditions | Lighting conditions, ΔE color measurement |
| ASTM B117 | Standard Practice for Operating Salt Spray (Fog) Apparatus | Corrosion resistance of surface finishes |
| AS9102B / AIAG PPAP 4th Ed. | First Article Inspection / Production Part Approval Process | FAI report, PPAP Level 3 |
| EU RoHS 2011/65/EU | Restriction of Hazardous Substances in Electrical & Electronic Equipment | Material compliance for EU market |
| As-Cast Tolerance±0.1 mm / 25 mm | Post-CNC Machined±0.05 mm | Tightest Achievable±0.003 in | Press Force Availability150T to 1200T |
| Tolerance Type | Description | Governing Standard |
|---|---|---|
| Linear Dimensional Tolerance | Length, width, height, diameter — measured within one die half | NADCA 4-6, ISO 8062-3 |
| Parting Line Tolerance | Dimensions spanning the parting plane between opposing die halves | NADCA Section 4 (Projected Area) |
| Draft Angle | Required taper on surfaces parallel to die draw direction to enable ejection | NADCA, DFM Guidelines |
| Geometric Tolerances (GD&T) | Flatness, true position, perpendicularity, runout, cylindricity, etc. | ASME Y14.5-2018, ISO 1101 |
| Alloy Composition | Elemental percentages per ASTM specification; verified by XRF spectrometer | ASTM B85 / B86 / B94 |
| Material Hardness | Brinell (HB) or Rockwell (HRB) hardness in as-cast condition | ASTM E10 / E18 |
| Nominal Dimension | Grade 1 — Standard (±mm) | Grade 2 — Precision (±mm) | Notes |
|---|---|---|---|
| 0 – 25 mm (0–1 in) | ±0.18 | ±0.10 | Al & Zn alloys |
| 25 – 63 mm (1–2.5 in) | ±0.25 | ±0.15 | +0.001″ per additional inch |
| 63 – 152 mm (2.5–6 in) | ±0.35 | ±0.20 | — |
| 152 – 254 mm (6–10 in) | ±0.45 | ±0.28 | — |
| 254 – 406 mm (10–16 in) | ±0.60 | ±0.38 | — |
| 406 – 610 mm (16–24 in) | ±0.80 | ±0.50 | Consult VNcontx Engineering |
| Mg alloy (all ranges) | ±0.25 – ±0.80 | ±0.15 – ±0.50 | Different shrinkage rate; calculate separately |
| Projected Area | Area Tolerance (+in) | Total Parting Line Tolerance |
|---|---|---|
| 0 – 10 in² | +0.005″ | Linear tol + 0.005″ |
| 10 – 25 in² | +0.008″ | Linear tol + 0.008″ |
| 25 – 50 in² | +0.010″ | Linear tol + 0.010″ |
| 50 – 100 in² | +0.012″ | Linear tol + 0.012″ |
| 100 – 200 in² | +0.016″ | Linear tol + 0.016″ |
| > 200 in² | +0.020″ | Consult VNcontx Engineering |
| Surface Type | Minimum Draft | Recommended |
|---|---|---|
| Exterior walls (draw direction) | 1° | 2° – 3° |
| Internal cores / cavities | 2° | 3° – 5° |
| Textured surfaces | 3° (0.001″ depth per 1°) | 4° – 5° |
| Deep holes / blind bosses | 0.5° per side | 1° per side |
| Zero-draft features | 0° — requires post-cast CNC machining | Redesign recommended if possible |
| Characteristic | Symbol | As-Cast | Post-CNC | Notes |
|---|---|---|---|---|
| Flatness | ⌷ | 0.30 mm / 100 mm | 0.08 mm | Mating surfaces as-cast: 0.10 mm |
| Straightness | ⌬ | 0.25 mm / 100 mm | 0.05 mm | — |
| Circularity | ○ | 0.15 mm | 0.03 mm | Precision bores post-CNC: 0.025 mm |
| Cylindricity | ⶭ | 0.20 mm | 0.05 mm | — |
| Perpendicularity | ⊥ | 0.30 mm / 100 mm | 0.08 mm | — |
| Parallelism | ∥ | 0.30 mm / 100 mm | 0.08 mm | — |
| True Position | ⊕ | Ø0.50 mm | Ø0.15 mm | 3-datum reference frame required |
| Concentricity | ◎ | 0.30 mm | 0.08 mm | — |
| Total Runout | ⌰ | 0.25 mm TIR | 0.05 mm TIR | — |
| Profile of a Surface | ⌓ | 0.50 mm | 0.15 mm | Complex freeform surfaces |
| Alloy | ASTM | Primary Composition (%) | Impurity Limits | HB |
|---|---|---|---|---|
| A380 (Al) | B85 | Al ~83%, Si 7.5–9.5%, Cu 3.0–4.0% | Fe ≤1.3%, Mn ≤0.5%, Mg ≤0.10% | 75–95 |
| A383 (Al) | B85 | Al ~84%, Si 9.5–11.5%, Cu 2.0–3.0% | Fe ≤1.3%, Zn ≤3.0% | 74–90 |
| A360 (Al) | B85 | Al ~89%, Si 9.0–10.0%, Mg 0.40–0.60% | Cu ≤0.6%, Fe ≤2.0% | 65–80 |
| ADC12 (Al) | JIS H5302 | Al ~85%, Si 9.6–12.0%, Cu 1.5–3.5% | Fe ≤1.3%, Mn ≤0.5% | 75–95 |
| Zamak 3 (Zn) | B86 | Zn 95.6–96.4%, Al 3.9–4.3%, Mg 0.03–0.06% | Pb ≤0.003%, Cd ≤0.003% | 82 |
| Zamak 5 (Zn) | B86 | Zn 94.1–95.5%, Al 3.9–4.3%, Cu 0.75–1.25% | Pb ≤0.003%, Cd ≤0.003% | 91 |
| AZ91D (Mg) | B94 | Mg ~90%, Al 8.5–9.5%, Zn 0.45–0.90% | Cu ≤0.030%, Ni ≤0.002%, Fe ≤0.005% | 63–70 |
| Item | Requirement | Governing Standard |
|---|---|---|
| CMM Room Temperature | 20°C ± 1°C | ISO 1 / ASME B89.6.2 |
| CMM Accuracy (MPE) | ≤ 1.7 + L/333 µm (L in mm) | ISO 10360-2 |
| Sampling Points — Plane | ≥ 9 points (min. 3×3 grid) | ISO 10360 |
| Sampling Points — Bore | ≥ 8 pts per cross-section; ≥ 2 cross-sections | ASME Y14.5 |
| Probe Calibration | Daily before each shift; mandatory after any collision event | ISO 10360-5 |
| Fixturing | No induced distortion permitted — soft jaw or dedicated fixture required | — |
| FAI Report | Full dimensional balloon layout per drawing | AS9102B / AIAG PPAP Level 3 |
| X-Ray Testing | ASTM E505; max porosity Grade 2 per NADCA | ASTM E505 / E1030 |
| Hardness — A380 | HB 75–95; 5 measurement locations per part | ASTM E10 (Brinell) |
| Salt Spray Test | 96 h or 240 h; representative sample per production lot | ASTM B117 |
| Tensile Strength (when specified) | A380: UTS ≥ 317 MPa; Yield ≥ 159 MPa | ASTM B557 |
| Standard | Full Title | Application |
|---|---|---|
| NADCA Product Spec 4-6 | North American Die Casting Association — Engineering & Design Standards | Linear tolerances, parting line, draft angle |
| ISO 8062-3:2007 | GPS — Tolerances for Castings, Part 3 | Dimensional and geometric tolerances |
| ASME Y14.5-2018 | Dimensioning and Tolerancing | GD&T on ASME drawings |
| ISO 1101:2017 | Geometrical Product Specifications — Geometrical Tolerancing | GD&T on ISO drawings |
| ASTM B85 / B86 / B94 | Al / Zn / Mg Die Casting Alloy Specifications | Alloy composition per material family |
| AS9102B / AIAG PPAP 4th Ed. | First Article Inspection / Production Part Approval Process | Aerospace & automotive programs |
| ISO 10360-2 | Acceptance and Reverification Tests for CMM | CMM qualification and periodic calibration |
| ASTM B117 | Standard Practice for Operating Salt Spray (Fog) Apparatus | Surface finish corrosion resistance testing |
| EU RoHS 2011/65/EU | Restriction of Hazardous Substances Directive | Material compliance — EU market |
High-integrity prototype parts engineered for functional testing and design validation — delivered at production-grade material spec.
Direct technical escalation from the floor — mold flow analysis, critical ECO management, and GD&T tolerance review at every stage.
Hardened steel tooling options for early-stage prototyping with DFM integrity review and Cpk/Ppk sign-off before first shot.
VNcontx provides a complete ecosystem of high-pressure casting, certified alloys, and industrial-grade finishes — engineered for global export.
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High Pressure Die Casting
Molten metal injected into hardened steel dies at 1,000–20,000 PSI. Fastest cycle times, tightest dimensional tolerances.
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Low Pressure Die Casting
Low-pressure inert gas (7–30 PSI) drives melt upward into the die. Superior for wheels, structural frames, uniform density.
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Hot & Cold Chamber
Hot-chamber for zinc/magnesium — fast cycle, submerged piston. Cold-chamber for aluminum/copper — handles high-melting alloys.
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Advanced Design Software
Mold-flow simulation, ProE/SolidWorks CAD, CAM toolpath optimization. DFM review included before first tool cut.
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Aluminum AlloysADC12, A380, A383, A360 — industry-standard HPDC alloys. ADC12 dominates automotive; A380 excels in complex geometry; A360 for superior corrosion resistance. Spec: JIS H5302 / ASTM B85 |
Zinc AlloysZamak 3, Zamak 5 — exceptional fluidity for thin-wall sections ≥0.5mm. Zamak 5 adds copper for higher strength and hardness in load-bearing parts. Spec: ASTM B86 / EN 1774 |
Magnesium AlloysAZ91D, AM60B — lightest structural casting metal. Best strength-to-weight in portable electronics, EV housings, aerospace brackets. Spec: ASTM B94 / ISO 16220 |
Copper AlloysHigh tensile strength, hardness, and corrosion resistance. Used in electrical connectors, hydraulic valves, marine plumbing fittings. Spec: ASTM B176 |
Lead & Tin AlloysHigh density (11.3 g/cm³), exceptional corrosion resistance. Specified for radiation shielding, counterweights, and precision bearings. Spec: ASTM B23 / ASTM B749 |
Silicon TombacBrass-silicon alloy — superior casting flow, high tensile strength (~500 MPa), premium surface for decorative and sanitary hardware. Spec: EN 1982 CC499K |
As-CastDirect from die — no secondary treatment. Natural die-cast texture, Ra 1.6–3.2 µm. Most cost-effective for internal structural parts. Spec: ISO 1302 (Surface Texture) |
Bead BlastingFine glass beads at controlled velocity create uniform matte. Eliminates parting lines, gate marks, ejector pin witness. Spec: SAE J444 / AMS 2431 |
Powder CoatingElectrostatic dry powder, cured at 180–200°C. Impact and UV resistant. Any RAL/Pantone. Thickness 60–100 µm. Spec: ASTM D3359 / ISO 2409 |
AnodizingElectrochemical oxide layer on aluminum. Type II (decorative, 5–25 µm) or Type III Hard Anodize (25–75 µm, Rockwell 60–70 HRC equiv.). Spec: MIL-A-8625F Type II/III |
Chromate ConversionChemical conversion coating on aluminum and zinc. Improves paint adhesion 3–5×, salt-spray resistance >168 hrs. RoHS/REACH compliant. Spec: MIL-DTL-5541F Class 1A/3 |
ElectroplatingNickel, chrome, or copper deposited 5–50 µm. Enhances hardness (Ni: ~500 HV), solderability, and cosmetic appearance. Spec: ASTM B456 / ISO 1456 |
Painting / Liquid CoatWet-spray primer + topcoat. Any RAL or Pantone. 2K polyurethane or epoxy base for chemical resistance in harsh environments. Spec: ISO 12944 Corrosivity Class C3–C5 |
Tumbling / VibratoryMass finishing in abrasive media — deburrs, radiuses edges, polishes to Ra 0.4–0.8 µm. Ideal for batch runs of small complex parts. Spec: ISO 9013 / MIL-STD-171 |
ImpregnationVacuum-pressure resin fills micro-porosity in HPDC castings. Critical for hydraulic housings, coolant manifolds, pressure-tight enclosures. Spec: MIL-STD-276A / SAE AMS 2766 |
| Low Pressure Die Casting | VS | High Pressure Die Casting |
|---|---|---|
| 5 – 30 PSI | Injection Pressure | 1,000 – 20,000 PSI |
| Slow | Injection Speed | Fast (10–100× LPDC) |
| Faster Cooling Rate | ||
| Lower Secondary Dendrite Arm Spacing (SDAS) | ||
| > 0.18 in | Recommended Wall Thickness | 0.04 – 0.16 in |
| Higher Dimensional Accuracy | ||
| Yes | Undercuts Possible | No |
| Better Suited for Complex Geometries |
Direct factory sourcing from Vietnam to eliminate middleman margins. VNcontx partners with you for a comprehensive cost-down analysis.
On-site Manufacturing Engineers, SQEs, and Tooling Experts assigned to your program.
Full program compliance including APQP, PPAP Level 3. Integrated automation to maintain zero-defect standards.