on die-castings
The quality of a die-cast component does not depend on a single stage, but on the integration of multiple processes and the control of the process as a whole.
Metalfusioni manages the main processes involved in aluminium die-casting, offering the customer a single technical reference and a greater oversight of the quality, lead times and reliability of the final product.
The Metalfusioni method
Mould design and production
Mould design is a crucial stage for casting quality and production stability.
Metalfusioni supports the customer in the design and management of mould production, ensuring consistency between the mould, requirements.
An approach that allows us to:
- reduce critical issues during the start-up phase
- improve process repeatability
- optimise production over time
Aluminium die-casting
Aluminium die-casting enables the production of complex components with high dimensional accuracy and consistent quality.
Metalfusioni specialises in the production of aluminium die-castings for industrial applications requiring reliability, production continuity and compliance with technical specifications.
The casting process is carried out using temperature-controlled moulds, with automated presses assisted by anthropomorphic robots, and is organised to ensure consistent quality and uniformity across production batches.
Surface finishes
The deburring, shearing, tumbling and sanding of aluminium die-castings enable the removal of excess material and surface imperfections, the improvement of the appearance and the standardisation of the component finishing. At Metalfusioni, manual deburring and shearing using 15/20-tonne shears, together with tumbling and sanding processes, are essential for improving the die-casting functional and aesthetic quality, preparing it for subsequent treatments and ensuring it complies with dimensional specifications.
Surface finishes complete the component by improving its strength, durability and appearance; the choice is made considering the end use, the application sector and the technical and quality requirements. The main processes include powder and liquid coating, chrome plating, polishing and impregnation.
Mechanical processing
Mechanical processing of aluminium enables the achievement of precise tolerances and specific functionalities required by the end application.
Metalfusioni manages these processes as an integral part of the production cycle, guaranteeing:
- dimensional accuracy
- consistency with the design
- reliability of the component within the customer’s production environment
Casting radioscopic and tomographic inspection
Radioscopic and tomographic inspection of aluminium castings allows the internal integrity of the component to be verified without altering its structure.
These non-destructive tests enable:
- the identification of any internal defects
- the reduction of the non-conformity risk
- the increase in the reliability of the final product
An essential tool for industrial production requiring high quality standards.
Dimensional checks
Dimensional inspections are an essential step in ensuring that every component strictly complies with design specifications. Metalfusioni performs thorough inspections using high-precision measuring instruments capable of detecting even the slightest deviations from nominal dimensions.
Inspection activities are carried out both during the production process and on the finished product, with the aim of ensuring consistent quality and compliance with the required technical specifications.
This approach allows us to maintain high standards of reliability and meet application requirements even in the most demanding contexts.
Warehousing and production continuity
Mold management and their availability over time are key factors in supporting continuous industrial production.
At Metalfusioni, mold storage and management are designed to ensure operational continuity, support customer scheduling, and reduce production restart times.
Each mold is identified, coded, and tracked internally to ensure proper long-term management, production repeatability, and consistency with customer requirements.
The right material for every project
Metalfusioni produces die-cast aluminium components using a range of alloys, selected according to the specific application and the customer’s requirements, with casting weights ranging from 8 grams to 4 kg.
The choice of the alloy is a key factor in determining mechanical performance, component durability and compatibility with the production process.
Our technical expertise enables us to identify the most suitable solution based on the industrial context of use.
Alloys used
- Aluminium alloy EN AB 46000 Al Si 9 Cu3 (Fe)
- Aluminium alloy EN AB 46100 Al Si 11 Cu2 (Fe)
- Aluminium alloy EN AB 47100 Al Si 12 Cu1 (Fe)
- Aluminium alloy EN AB 44300 Al Si 12 (Fe)
- Aluminium alloy Unifont 94 GD Al Zn 10 Si 8 Mg "C"
- Aluminium alloy 5080 GD Al Mg 7.5 (Fe)
- Zamak alloy ZnAl4Cu1
Quality control
Quality is not a final check, but a constant process throughout the several production stages. A fundamental approach to ensuring reliability, repeatability and stability in aluminium die-casting.
Industrial sectors
We work with medium-large businesses operating in technical and manufacturing environments where precision, reliability and continuity are essential requirements.
Let’s have a look at your project
Are you looking for a reliable partner for aluminium die-casting and the management of continuous
flow industrial production?