Views: 109 Author: Site Editor Publish Time: 2026-03-13 Origin: Site
Our company specializes in high-quality custom metal components, including zinc alloy die-casting, aluminum alloy die-casting, other metal casting products, as well as CNC machining, stamping,forging and surface treatment services, all tailored to meet our clients’ specific requirements. This case highlights our ability to resolve a critical quality challenge for a client whose products—used in high-standard hospital wards—depend on precision die casting.
The client, a leading manufacturer of medical equipment accessories, required custom zinc die-casting panels for gas outlets in hospital wards—parts expertly crafted through professional die casting. These panels demand powder coating for enhanced durability, corrosion resistance, and a smooth finish, yet the client repeatedly reported coating damage shortly after the initial delivery of the die casting parts.
The primary issues included frequent scratches, chipping, and uneven coating surfaces. In hospital environments—where hygiene and visual appearance are paramount—even minor defects were unacceptable, as they compromised ward aesthetics, posed corrosion risks to the die casting parts, shortened their service life, and resulted in high scrap rates and increased costs for both parties.
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Our cross-functional team, consisting of die casting engineers, surface treatment technicians, and quality control experts, conducted a thorough investigation and identified three root causes: inconsistent powder coating processes, insufficient post-coating testing, and inadequate packaging for the die casting parts.
We implemented targeted improvements to address these issues:
1) Optimized the powder coating process specifically for die casting parts—refining pre-treatment steps (degreasing, de-rusting, phosphating) to enhance coating adhesion, adjusting equipment parameters (spray pressure, powder flow, curing temperature) for uniform coverage, and sourcing medical-grade, scratch-resistant powder ideal for zinc die casting components.
2) Strengthened post-coating testing to meet strict industry standards: ISO 2409 0-class adhesion (no coating flaking during cross-cut and tape tests); 2H pencil hardness (a significant improvement from the original 1B rating); ASTM D2794 impact resistance (1kg weight dropped from 50cm with no chipping or cracking); and ASTM B117 neutral salt spray resistance (48 hours of continuous exposure, exceeding the client’s 24-hour requirement). 100% batch inspection was implemented to ensure all die casting parts met flawless quality standards.
3) Upgraded packaging to protect the finished die casting parts during transportation and handling: anti-scratch bubble wrap for each part and thick corrugated boxes with custom inserts for carton packaging, supplemented by clear "handle with care" labels to minimize damage.Then use wooden case to put these cartons to avoid any other potential risks during transportation.
Trial die casting products underwent rigorous client inspection and passed with flying colors. In the months that followed, no further coating-related complaints were received, and the scrap rate for die casting parts plummeted from 15% to less than 1%. This outcome not only resolved the client’s core pain points but also strengthened our long-term partnership in custom die casting solutions.
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This case demonstrates our expertise in addressing quality challenges in die casting and delivering reliable, custom die-casting solutions for high-standard medical applications. We remain committed to continuous process improvement and delivering high-quality, tailored die casting parts that exceed our clients’ expectations.
