Enhancing Product Air Tightness and Mass Production Stability Through Local Squeeze Technology
1. Customer Challenge: Air Leakage Issue Affecting Mass Production Stability
In automotive high-pressure die casting production, internal casting quality plays a critical role in ensuring machining performance and product reliability.
During the mass production phase of a Honda oil pan project, air leakage defects were detected during the air tightness test. Since the affected area required post-machining, internal casting defects were exposed after machining, resulting in leakage between two machined holes.
Based on production data from Project A:
Before implementing local squeeze technology, the average air leakage defect rate reached 8.47%.
The continuous leakage issue increased scrap and rework costs, while also creating risks to production efficiency, delivery schedules, and long-term product reliability.
2. Root Cause Analysis: Identifying the Connection Between Casting Structure and Leakage
After receiving customer feedback, the Raidy engineering team conducted a detailed investigation, including product dissection and defect location analysis.
The analysis of the leakage area revealed:
- The wall thickness after machining was only 3 mm;
- Internal casting structure in the area was loose with potential porosity;
- During machining, the hidden internal pores were opened and connected between two holes;
- This connection created an air leakage path during the air tightness test.
Further investigation determined that the leakage was not caused by machining conditions, but by insufficient local feeding and internal density during the die casting process.
Therefore, adjusting machining parameters alone could not permanently solve the issue. A mold structure improvement was required to address the problem at the source.
3. Raidy Solution: Adding a Local Squeeze Pin to Improve Internal Density
For the severe leakage area A, Raidy’s engineering team proposed a targeted mold modification:
Addition of a Local Squeeze Pin
A squeeze pin was added to the corresponding area of the die casting mold. During the critical solidification stage, the squeeze pin applies additional pressure to improve local feeding and enhance material density.
Improvement Mechanism:
- Improves local shrinkage compensation capability;
- Reduces internal porosity and looseness;
- Enhances casting structure integrity;
- Minimizes the risk of air leakage after machining.
Compared with traditional process parameter adjustments, the local squeeze solution directly targets the defect area and provides a more effective and sustainable improvement without major changes to the overall mold structure.
4. Improvement Results: Significant Reduction in Leakage Rate and Improved Production Reliability
After mold modification and mass production validation, the air leakage performance was significantly improved.
Production data showed that:
- The leakage rate after mold improvement was significantly lower compared with previous production months;
- Product air tightness stability was greatly enhanced;
- Customer quality losses caused by leakage defects were reduced;
- The project achieved more stable mass production.
This improvement demonstrated that optimized mold design and localized squeeze technology can effectively solve internal casting quality issues and improve the reliability of automotive die-cast components.
5. Customer Value: More Than Problem Solving — Creating Long-Term Manufacturing Benefits
For automotive component manufacturers, a die casting mold is not only a production tool, but also a key factor influencing product quality, manufacturing cost, and production stability.
Through Raidy’s local squeeze improvement solution, the customer achieved:
✅ Reduced Quality Risk
Lower risk of leakage defects, scrap, and rework caused by internal casting porosity.
✅ Improved Production Efficiency
Reduced downtime, troubleshooting activities, and additional inspection costs.
✅ Enhanced Mass Production Stability
Improved product consistency and reliability to meet automotive quality requirements.
✅ Optimized Manufacturing Cost
Prevented repeated trial-and-error improvements after production launch through early mold structure optimization.
6. Raidy Capability: From Mold Manufacturing to Die Casting Problem Solving
As a professional high-pressure die casting mold manufacturer, Raidy provides more than mold fabrication. We support customers throughout the entire product development and mass production process by solving complex casting challenges.
With expertise in:
- Mold flow analysis optimization;
- Advanced die casting mold design;
- Local squeeze technology application;
- Casting defect analysis;
- Mass production improvement;
Raidy helps customers reduce manufacturing risks and achieve stable, efficient, and high-quality production.
A high-quality mold is not only a manufacturing tool — it is the foundation of product reliability and customer competitiveness.
