What is your minimum order quantity for custom parts?

We support single-piece prototypes and low-volume runs through CNC machining, 3D printing and urethane casting, and scale to mass production through die casting, injection molding and stamping. Share your target quantity and our engineers will recommend the most cost-effective process.

What tolerances can Sunmy Hardware hold?

Standard CNC tolerances are ±0.01 mm, and critical features can be held down to ±0.005 mm. Dimensions are verified with CMM inspection and documented in FAI reports before shipment.

How do you protect my drawings and intellectual property?

We sign a Non-Disclosure Agreement with you by email before collecting any 3D or CAD files. You work directly with the factory, so your data is never handed off to brokers.

Which quality documents are available with shipments?

Material certificates, RoHS compliance documents, First Article Inspection (FAI) reports and CMM dimensional reports can be supplied per project.

Which manufacturing processes are done in-house?

CNC machining and stamping are performed in our own facilities. Casting and surface finishing are completed by audited partners. All final quality control, CMM inspection and FAI are executed in-house by Sunmy engineers before global shipping.

Which CAD file formats do you accept?

We accept STEP, IGES, STL, DWG/DXF and PDF 2D drawings. Physical samples can also be reverse-engineered.

Custom Die Cast Aluminum Finned Housings End Caps OEM Manufacturer High Quality Aluminum Die Casting Enclosures Factory Supplier

Product Overview

Keep your mounting layout. Customize the casting around it. Shenzhen Sunmy Hardware Co., Ltd. manufactures die-cast aluminum finned housings and end caps to customer drawings or samples, combining high-pressure die casting with secondary CNC turning and milling. Specify the flange, internal cavity, fitting diameters, groove profiles and threaded connections to suit your assembly. Supply can cover machined castings, coated housings or agreed mechanical subassemblies; motors, bearings, seals and electrical components are included only when listed in the quotation.

Target OEM Projects: FHP/BLDC motor housings, appliance drives, robotic actuators and compact electromechanical assemblies. Reference images illustrate housing geometry; the end use, bearing-seat function and connection standards are confirmed from the project drawing.

Manufacturing & Engineering Insights

One coordinated route from casting to finished part: review tooling, machining allowances, locating datums and coating boundaries before production. The approved drawing and inspection plan define the acceptance requirements.

High-Pressure Die Casting (HPDC)

Select ADC12, A380 or a specified aluminum alloy by its governing material standard. Gate and vent design, draft, wall transitions and local porosity requirements are reviewed before tooling. Simulation and casting acceptance criteria are agreed for the project.

Secondary Precision CNC Machining

Machine bearing seats where specified, pilot diameters, mating faces, holes and threads against defined datums. Use common-setup machining where geometry allows. Diameter fit, runout, flatness and hole position are separate requirements; critical tolerances are reviewed feature by feature.

Seal Interfaces & Fastener Seats

Define groove dimensions and finish from the selected seal and mating part. Counterbores are sized to the chosen fastener; screw-seat geometry alone does not ensure resistance to loosening. Groove machining does not establish an IP rating.

Surface Finishing & Masking

Specify e-coat or powder coat by system, thickness, appearance and coverage. Mask fits, threads and designated contact areas, or agree post-coating machining. Salt-spray testing requires a specified exposure period, evaluation method and acceptance criterion.

Technical Specifications

Parameter	Custom Options / Project Requirements
Product Name	Custom Die Cast Aluminum Finned Housing / End Cap
Manufacturing Process	High-Pressure Die Casting (HPDC) + CNC Turning, Milling, Drilling & Threading
Material Options	Aluminum: ADC12, A380, A360, AlSi9Cu3 or AlSi10Mg, subject to alloy/process review. Zamak 3/5 alternatives require separate design approval.
Tolerances & Fits	Casting grade and edition agreed per ISO 8062. CNC: ±0.01–0.02 mm reference targets on selected features. Bore fits and geometric limits specified separately.
Surface Roughness	Review targets: as-cast Ra 3.2–6.3 µm; machined Ra 0.8–1.6 µm; bearing seats Ra 0.8 µm where specified. Confirm by surface and process.
Surface Finishing	E-coating, powder coating, blasting or chemical conversion treatment. Anodizing subject to alloy suitability and sample approval.
Leak Testing & Ingress Protection	Grooves and mating faces to the selected seal. Leak-test criteria and any IP54/IP65/IP67 requirements use separately agreed procedures for the relevant assembly.
Thermal Geometry	Fin count, spacing, height, thickness and airflow clearance customized to the drawing. Temperature rise and heat rejection verified in the intended assembly.
Critical Interfaces	Flange/pilot dimensions, bores or specified bearing seats, threaded boss, groove profile and mounting holes. Four- or six-hole patterns are examples, not limits.
Inspection & Documentation	Dimensional, thread and surface checks per agreed inspection plan. Sampling, FAI, material/coating records and required certification evidence confirmed at quotation.
Prototype & Tooling Schedule	Planning references: CNC fit-check samples 3–5 days; tooling and T1 cast samples 20–25 days. Confirm material, finish, trial scope and delivery schedule.
Production & Order Quantities	Reference production window: 15–25 days after approval. Pilot and repeat quantities, coating and inspection scope determine the confirmed schedule and order minimum.
Packing & Delivery	Protect fits, threads and coated faces with separators or EPE foam trays. Reinforced export cartons; pallets and additional protection as specified.

Key Engineering Features & OEM Advantages

Fin Geometry Matched to the Application: Adjust fin layout to the installation envelope, casting fill and available airflow. Thermal performance is evaluated with the actual heat source, mounting interface and environment, rather than inferred from the appearance or number of fins.
Defined Fits, Not Blanket Precision: Datum-based machining and agreed gauges focus inspection on the interfaces that control assembly. A runout target below 0.015 mm can be reviewed for selected features. Bore size is controlled separately; motor noise and service life require assembly-level evaluation.
Seal and Coating Decisions Made Together: Agree groove finish, masking, mating surfaces and test conditions before production. Quote bare castings, finish-machined housings and coated parts as distinct supply conditions so sample approval matches the production order.
Ribs and Wall Sections to Suit the Design: Review wall thickness, reinforcement and machining stock against loads and tooling constraints. Evaluate proposed geometry changes before tool manufacture; prototype fit checks and production casting trials serve different approval purposes.
Drawing-to-Part with Matching Components: Customize contours, fins, bores, flanges, threads and finishes from drawings or samples. Coordinate castings, turned fittings, stamped parts and molded components in one defined package. Send the housing drawing, mating-part details, material, finish and quantities for quotation.

Technical FAQ for Sourcing & Engineering Teams

Q1: How do you control bearing fits and interface alignment?

A: Start with the specified bearing, bore diameter and assembly requirements. H7 defines a hole-size tolerance that changes with nominal diameter; it is not a runout or concentricity requirement. Define those geometric controls separately with their datums. We agree the machining route, gauging method and reporting scope before production.

Q2: Can leak testing be included for sealed housings?

A: Leak testing can be scoped during the project review. Specify the method, test medium, pressure, stabilization time, allowable leak rate and fixture sealing locations. Air pressure-decay testing and helium leak testing are different methods. Test capability and reporting are confirmed at quotation; IP dust/water testing of the configured assembly is a separate acceptance step.

Q3: What are the prototype, tooling and production lead times?

A: Planning references are 3–5 days for CNC samples, 20–25 days for tooling and T1 cast samples, and 15–25 days for production after approval. The quotation confirms the schedule, including finishing, trials and inspection. CNC fit-check samples do not validate production casting porosity or the performance of a different alloy.

Q4: Can you customize from drawings or samples before tooling?

A: Yes. Send STEP/IGES models and dimensioned PDF/DXF drawings, or a sample with mating-part information. We review fin layout, draft, wall transitions, machining stock, coating allowances and inspection access. Mold-flow analysis can be included where required. Proposed changes need your approval; tooling cost, sample quantities and repeat-order volumes are quoted to the project.

Q5: What aluminum alloy materials and surface treatments are available?

A: Aluminum options include ADC12, A380, A360, AlSi9Cu3, or AlSi10Mg subject to alloy and process review. Available surface treatments include E-coating, powder coating, shot blasting, and chemical conversion treatments, tailored to defined exposure periods and corrosion resistance criteria.

Q6: How is thermal fin performance verified for custom housings?

A: Fin count, spacing, height, thickness, and airflow clearance are customized directly from your drawings. Thermal performance, heat rejection, and temperature rise are evaluated using your specific heat source, mounting interface, and intended operating environment.

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