Blog

Sheet metal stamping is the backbone of countless industries—from automotive and electronics to industrial equipment. But even the most innovative product designs can fail at the production stage if they ignore Design for Manufacturability (DFM) principles. At Shenzhen Sunmy Hardware Co., Ltd., a leading Shenzhen-based 工贸 (industry-trade integrated) foreign trade company founded in 2016, we’ve seen firsthand how small DFM oversights lead to delayed timelines, inflated costs, and compromised part quality for our global clients.​With our end-to-end production ecosystem—covering Casting, Lathe, Machining, Stamping, and Injection Molding—and a team specializing in custom part manufacturing (backed by robust R&amp;D capabilities), we help clients turn design concepts into tangible, high-quality products. Today, we’re sharing the 5 most common DFM mistakes in sheet metal stamping design, plus actionable fixes to keep your projects on track. Let’s dive in.​<figure id="figure-hlxwex4svemg0r2rp8"><img id="hlxwex4svemg0r2rp8" src="https://cdn.durable.co/blocks/12yaHyWOuMH7KjcGxn3th6JVHgmKZtfwCXIwf2Pe3h4MqYp5n8zsd1Yaj9mjisNL.png" alt=" 5 DFM Mistakes Overview Infographic" title=" 5 DFM Mistakes Overview Infographic" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 1/1; object-position: 50% 80%;" data-corners="default" data-aspect="1:1" data-caption=" 5 DFM Mistakes Overview Infographic" data-positionx="50%" data-positiony="80%" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/12yaHyWOuMH7KjcGxn3th6JVHgmKZtfwCXIwf2Pe3h4MqYp5n8zsd1Yaj9mjisNL.png" data-mce-style="aspect-ratio: 1/1; object-position: 50% 80%;"><figcaption class="body-normal text-gray-500 mt-2">5 DFM Mistakes Overview Infographic</figcaption></figure><h3>1. Neglecting Minimum Bend Radius: A Recipe for Material Failure​</h3>The Mistake:​Many designers specify bend radii smaller than the material can handle, assuming “tighter = better.” For example, a 1mm aluminum sheet with a 0.5mm bend radius might seem efficient, but it risks cracking, warping, or weakening the material’s structural integrity.​<figure id="figure-jmvofouu5emg0r52ku"><img id="jmvofouu5emg0r52ku" src="https://cdn.durable.co/blocks/cbFIJ93hjkVXXRm9iXriJUaPhdy8cESgIQBZ3G0mZAipoq2aYMrs3g0Idfl30QNd.png" alt="Bend Radius (Wrong vs. Correct)" title="Bend Radius (Wrong vs. Correct)" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 1/1; object-position: undefined undefined;" data-corners="default" data-aspect="1:1" data-caption="Bend Radius (Wrong vs. Correct)" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/cbFIJ93hjkVXXRm9iXriJUaPhdy8cESgIQBZ3G0mZAipoq2aYMrs3g0Idfl30QNd.png" data-mce-style="aspect-ratio: 1/1; object-position: undefined undefined;"><figcaption class="body-normal text-gray-500 mt-2">Bend Radius (Wrong vs. Correct)</figcaption></figure>The Consequences:​<ul><li>Scrap rates spike as parts fail quality checks.​ </li><li>Rework delays production (we’ve seen projects pushed back 2–3 weeks due to this issue).​ </li><li>Compromised durability shortens the end product’s lifespan.​</li></ul>Sunmy’s Fix:​Our stamping engineers work directly with clients to align bend radii with material properties. For common materials:​<ul><li>Steel: Minimum bend radius = material thickness (t)​ </li><li>Aluminum: Minimum bend radius = 1.5t (to avoid cracking)​ </li><li>Stainless steel: Minimum bend radius = 2t (due to higher tensile strength)​</li></ul><span style="font-family: inherit; font-size: calc(18px * var(--body-fontSize, 1)); font-weight: inherit; font-style: var(--body-fontStyle, normal);" data-mce-style="font-family: inherit; font-size: calc(18px * var(--body-fontSize, 1)); font-weight: inherit; font-style: var(--body-fontStyle, normal);">With our in-house stamping equipment, we can also test prototype bends early—ensuring your design works before full-scale production.​<h3>2. Poor Hole Placement: Why “Too Close” Costs You Money​</h3>The Mistake:​Holes placed too near edges, bends, or other holes are a top culprit in stamping defects. A common error? A 5mm diameter hole just 3mm from a sheet edge—this creates weak points that cause tearing during stamping.​The Consequences:​<ul><li>Parts with cracked edges or deformed holes require manual repair (adding labor costs).​ </li><li>In extreme cases, entire batches are unusable (we once helped a client recover from a 500-unit scrap due to this mistake).​</li></ul><figure id="figure-px2w0wun9lmg0r8ll6"><img id="px2w0wun9lmg0r8ll6" src="https://cdn.durable.co/blocks/6VGqwXhhNpf1RNsyak1EpPfn2juMhbWcI2lcUoQ9nGNmlo4WuyTqLo7aXtjVe13S.png" alt="Hole Placement DFM Rules" title="Hole Placement DFM Rules" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: undefined undefined;" data-corners="default" data-aspect="16:9" data-caption="Hole Placement DFM Rules" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/6VGqwXhhNpf1RNsyak1EpPfn2juMhbWcI2lcUoQ9nGNmlo4WuyTqLo7aXtjVe13S.png" data-mce-style="aspect-ratio: 16/9; object-position: undefined undefined;"><figcaption class="body-normal text-gray-500 mt-2">Hole Placement DFM Rules</figcaption></figure>Sunmy’s Fix:​Follow these DFM guidelines (verified by our 8+ years of stamping experience):​<ul><li>Hole edge to sheet edge: Minimum distance = 1.5 × hole diameter​ </li><li>Hole edge to bend line: Minimum distance = 2 × material thickness + hole radius​ </li><li>Between two holes: Minimum distance = 2 × hole diameter​ </li></ul>Our team reviews your 2D/3D drawings (or physical samples) upfront to flag risky hole placements—saving you time and material waste.​<h3>3. Overly Tight Tolerances: When Precision Becomes a Liability​</h3>The Mistake:​Designers often specify tolerances tighter than necessary (e.g., ±0.01mm for a non-critical mounting hole) to “ensure quality.” But tight tolerances force stamping machines to operate at slower speeds and require more frequent calibration.​The Consequences:​<ul><li>Production costs increase by 20–40% (due to slower throughput and higher tool wear).​ </li><li>Lead times extend—we’ve seen a 4-week project turn into 6 weeks because of unnecessary tight tolerances.​</li></ul><figure id="figure-57osx1iq3amg0rbbah"><img id="57osx1iq3amg0rbbah" src="https://cdn.durable.co/blocks/105QwUXdqdzGJGqcGh0eMaDSX5nNzPlCJ2OIxqkxMYJkZejIdVhxTht5909GHAMM.png" alt="Tolerance Impact (Cost &amp; Lead Time Chart)" title="Tolerance Impact (Cost &amp; Lead Time Chart)" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: undefined undefined;" data-corners="default" data-aspect="16:9" data-caption="Tolerance Impact (Cost &amp; Lead Time Chart)" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/105QwUXdqdzGJGqcGh0eMaDSX5nNzPlCJ2OIxqkxMYJkZejIdVhxTht5909GHAMM.png" data-mce-style="aspect-ratio: 16/9; object-position: undefined undefined;"><figcaption class="body-normal text-gray-500 mt-2">Tolerance Impact (Cost &amp; Lead Time Chart)</figcaption></figure>Sunmy’s Fix:​We balance precision with practicality. Our engineers:​<ol><li>Identify critical vs. non-critical features (e.g., a hinge hole needs ±0.05mm, but a decorative hole can use ±0.2mm).​ </li><li>Align tolerances with our stamping equipment capabilities (our CNC stamping machines achieve consistent ±0.03mm for critical parts).​ </li><li>Propose cost-saving adjustments without sacrificing performance—keeping your project on budget and on schedule.​</li></ol><h3>4. Mismatched Material &amp; Stamping Process​</h3><figure id="figure-6kx1200oiimg0rdu6s"><img id="6kx1200oiimg0rdu6s" src="https://cdn.durable.co/blocks/1euGePGk4iRGIAfk3eXfMiusXDdZTsW0LDtzb4p1FBZYh1jiPGjW7LmGQyrkbI2v.png" alt="Material-Stamping Match Guide" title="Material-Stamping Match Guide" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: undefined undefined;" data-corners="default" data-aspect="16:9" data-caption="Material-Stamping Match Guide" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/1euGePGk4iRGIAfk3eXfMiusXDdZTsW0LDtzb4p1FBZYh1jiPGjW7LmGQyrkbI2v.png" data-mce-style="aspect-ratio: 16/9; object-position: undefined undefined;"><figcaption class="body-normal text-gray-500 mt-2">Material-Stamping Match Guide</figcaption></figure>The Mistake:​Choosing a material without considering stamping compatibility is a common pitfall. For example, using high-carbon steel (which is brittle) for complex, deep-draw stamping—or thin-gauge copper (which is soft) for high-impact parts.​The Consequences:​<ul><li>Material tearing during deep draws.​ </li><li>Parts that deform under stress (e.g., soft copper bending in a heavy-duty application).​ </li><li>Increased tool wear (abrasive materials like stainless steel damage dies faster).​</li></ul>Sunmy’s Fix:​Our material experts recommend options tailored to your design and application:​<ul><li>For complex bends: Low-carbonainless steel (durable, compatible with most stamping processes).​</li><li>For lightweight applications: 5052 aluminum (strong yet lightweight, ideal for electronics).​</li></ul>We source high-quality materials globally and test them in our in-house lab to ensure stamping compatibility.​<h3>5. Ignoring Post-Stamping Assembly Needs​</h3>The Mistake:​Designing a stamped part in isolation—without considering how it will assemble with other components—leads to costly rework. For example, a stamped bracket with a misaligned mounting hole that doesn’t fit a mating part.​<figure id="figure-lpx9d3apfbmg0rjbn0"><img id="lpx9d3apfbmg0rjbn0" src="https://cdn.durable.co/blocks/16YzBQFcBRs3vaGE3RUzOCLnG21wdKm4mXo7dE0OkGQIZPYX5PWrlkrOPFglVcl7.png" alt="Assembly-Focused Design (Misalignment vs. Alignment)" title="Assembly-Focused Design (Misalignment vs. Alignment)" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: undefined undefined;" data-corners="default" data-aspect="16:9" data-caption="Assembly-Focused Design (Misalignment vs. Alignment)" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/16YzBQFcBRs3vaGE3RUzOCLnG21wdKm4mXo7dE0OkGQIZPYX5PWrlkrOPFglVcl7.png" data-mce-style="aspect-ratio: 16/9; object-position: undefined undefined;"><figcaption class="body-normal text-gray-500 mt-2">Assembly-Focused Design (Misalignment vs. Alignment)</figcaption></figure>The Consequences:​<ul><li>Manual reaming or grinding to adjust parts (adding labor hours).​ </li><li>Delayed assembly lines (as teams wait for modified parts).​ </li><li>Frustration for your end users (if assemblies fail in the field).​</li></ul>Sunmy’s Fix:​We take a “system-level” approach. Our team:​<ul><li>Reviews your entire assembly (not just the stamped part) to check fitment.​ </li><li>Adds reference features (e.g., alignment notches) to simplify assembly.​ </li><li>Creates sample assemblies with your other components to verify compatibility before full production.​</li></ul><h3>Why DFM Matters—And How Sunmy Helps You Get It Right</h3><figure id="figure-yhixlh3p8wmg0ro3ry"><img id="yhixlh3p8wmg0ro3ry" src="https://cdn.durable.co/blocks/39fBC9Yqgc566aSrjjA0338ouLBtUaAoWreTpQHBnYBnJjBsl3TVkAp22pq8sr8H.png" alt="Sunmy DFM Workflow (From Design to Production)" title="Sunmy DFM Workflow (From Design to Production)" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: undefined undefined;" data-corners="default" data-aspect="16:9" data-caption="Sunmy DFM Workflow (From Design to Production)" data-positionX="undefined" data-positionY="undefined" data-fullWidth="false"/><figcaption class="body-normal text-gray-500 mt-2">Sunmy DFM Workflow (From Design to Production)</figcaption></figure>DFM isn’t just about avoiding mistakes—it’s about optimizing your design for cost, speed, and quality. At Shenzhen Sunmy Hardware, we’ve built our business around turning complex custom part requests into seamless production experiences. Our strengths:​<ul><li>End-to-end production: Casting, Lathe, Machining, Stamping, Injection Molding—all under one roof.​ </li><li>R&amp;D expertise: Our engineering team solves even the most challenging custom designs (we’ve turned 500+ client samples/drawings into mass-produced parts).​ </li><li>Global service: We support clients in North America, Europe, and Asia—with clear communication and on-time delivery.​</li></ul>Ready to fix your sheet metal stamping design and avoid these costly mistakes? Visit <a data-mce-href="sunmyhardware.com" href="sunmyhardware.com">sunmyhardware.com</a> to explore our stamping capabilities, view case studies, or submit your drawing/sample for a free DFM review. Our team is here to help you turn your design into a high-quality, cost-effective product.​ Got questions about your sheet metal stamping project? Drop us a line at <a data-mce-href="mailto:gavin@sunmyhardware.com" href="mailto:gavin@sunmyhardware.com">gavin@sunmyhardware.com</a> — we respond within 24 hours!​

5 Costly DFM Mistakes in Sheet Metal Stamping Design You’re Probably Making (And How to Fix Them)

<h2>Understanding Injection Molding</h2>
Injection molding is a popular manufacturing process used to produce parts by injecting molten material into a mold. This versatile technique is widely utilized in creating components for precision industrial applications due to its ability to produce complex shapes with high accuracy and repeatability. Whether you're new to the world of manufacturing or seeking to incorporate this process into your operations, understanding the basics of injection molding is essential.

At its core, injection molding involves several stages, including clamping, injection, cooling, and ejection. Each step plays a crucial role in ensuring the quality and precision of the final product. Mastery of these stages can significantly enhance the efficiency and output of manufacturing operations.

<figure id="figure-wlahttk2gjmfyydapl"><img id="wlahttk2gjmfyydapl" src="https://media.gettyimages.com/id/179078166/photo/injection-moulding-machine.jpg?b=1&s=2048x2048&w=0&k=20&c=KqZFPHq6gUXjuNlWLUa8KNiTEfsVV3z5SoEpnEwkdGE=" alt="injection molding machine" class="object-cover bg-gray-100" style="aspect-ratio: 16/9"></figure>

<h3>The Injection Molding Process</h3>
The injection molding process begins with the clamping stage, where the mold is securely closed to withstand the pressure of the molten material. Next, the injection phase involves forcing the molten plastic into the mold cavity. This requires precise control to ensure that the right amount of material fills every part of the mold.

Once the material cools and solidifies in the cooling phase, the mold opens, and the final product is ejected. This entire cycle can be completed in a matter of seconds, making injection molding an efficient method for mass production.

<h3>Materials Used in Injection Molding</h3>
A wide range of materials can be used in injection molding, each offering unique properties that suit different applications. Commonly used materials include thermoplastics like polypropylene, polyethylene, and polystyrene. These materials are favored for their durability, flexibility, and ease of molding.

<figure id="figure-uii04veglmfyydapl"><img id="uii04veglmfyydapl" src="https://media.gettyimages.com/id/1464656280/photo/plastic-water-bottles-sitting-piled-up-in-a-recycling-center.jpg?b=1&s=2048x2048&w=0&k=20&c=pgE93FaZ8dTgFuT1FE3gy-BP9fdMAmKPpKjpZMlV1w8=" alt="plastic materials" class="object-cover bg-gray-100" style="aspect-ratio: 16/9"></figure>

In addition to thermoplastics, some precision applications may require the use of specialty materials such as thermosetting plastics or elastomers. The choice of material often depends on factors such as strength requirements, temperature resistance, and cost-effectiveness.

<h3>Advantages of Injection Molding for Precision Applications</h3>
Injection molding offers several advantages that make it ideal for precision industrial applications. One of the primary benefits is its ability to produce high volumes of consistent parts with tight tolerances. This consistency is crucial in industries where precision and reliability are paramount.

Moreover, injection molding allows for design flexibility, enabling manufacturers to create intricate geometries that would be challenging with other methods. This flexibility extends to the surface finish of parts, which can be customized to meet specific aesthetic or functional requirements.

<figure id="figure-x6x5lf41qrmfyydapl"><img id="x6x5lf41qrmfyydapl" src="https://media.gettyimages.com/id/2224901743/photo/sheet-metal-bending-on-cnc-machine-gloved-worker-bending-a-metal-sheet-using-a-cnc-press.jpg?b=1&s=2048x2048&w=0&k=20&c=c9zNx7BETHX5bHLkNsOPJqtoA581ppWyF88MLdWGQr8=" alt="precision parts" class="object-cover bg-gray-100" style="aspect-ratio: 16/9"></figure>

<h3>Challenges and Considerations</h3>
While injection molding offers numerous benefits, it also presents challenges that must be addressed for successful implementation. One significant consideration is tool design and maintenance, which can be costly but is vital for maintaining quality over time.

Another challenge is the initial setup cost, as creating molds can be expensive. However, these costs are often offset by the efficiency and speed of production once the process is up and running.

<h3>Getting Started with Injection Molding</h3>
If you're considering adopting injection molding for your precision industrial applications, start by researching and selecting a reliable manufacturer or investing in high-quality equipment. Understanding your specific requirements and constraints will guide you in making informed decisions.

<figure id="figure-ogpagnofv7mfyydapl"><img id="ogpagnofv7mfyydapl" src="https://media.gettyimages.com/id/2211629470/photo/quantum-computing-quantum-superposition-quantum-physics-quantum-mechanics-science-data.jpg?b=1&s=2048x2048&w=0&k=20&c=H_F6c8TQVlGnScrChCaBiKXmN48rq7Kfqnqdz-15akU=" alt="manufacturing equipment" class="object-cover bg-gray-100" style="aspect-ratio: 16/9"></figure>

Additionally, collaborating with experienced engineers or consultants can provide valuable insights into optimizing your process for maximum efficiency and quality. With careful planning and execution, injection molding can become a vital component of your manufacturing strategy.

A Beginner's Guide to Injection Molding for Precision Industrial Applications

production line with customized items, Product Customization

<h2>Understanding Customized Production</h2>Customized production, also known as bespoke manufacturing, is a process where products are tailor-made to meet specific customer requirements. The idea of customizing products to suit individual needs has gained significant traction in recent years, thanks to advancements in technology and shifting consumer preferences. However, there are many misconceptions surrounding this approach that need clarification.<figure id="figure-ml3hiuvi5hmfxt9eii"><img id="ml3hiuvi5hmfxt9eii" src="https://cdn.durable.co/getty/0LPdUY8GrWokNvw0RCOJegaQnsYwBcFeAzASSq198ttu3Nz6mLVft4ZJwLY58EHi.jpeg" alt="customized production" title="customized production" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="customized production" data-positionX="null" data-positionY="null" data-fullWidth="false"/><figcaption class="body-normal text-gray-500 mt-2">customized production</figcaption></figure><h3>The Myths Surrounding Customized Production</h3>One common myth is that customized production is prohibitively expensive for both manufacturers and consumers. While it's true that bespoke items can carry a higher price tag than mass-produced counterparts, it is not universally the case. The cost largely depends on the complexity of the customization and the resources required.Another misconception is that customized production is only feasible for large companies with significant resources. In reality, small and medium-sized enterprises (SMEs) can also benefit from customization by leveraging digital tools and flexible manufacturing techniques. This allows them to offer personalized products without needing the scale of big corporations.<h3>Benefits of Customized Production</h3>One of the most significant benefits of customized production is the ability to meet specific customer needs. By tailoring products, companies can enhance customer satisfaction and foster brand loyalty. This approach can lead to higher customer retention rates and positive word-of-mouth marketing.<figure id="figure-h366ovpo0omfxt9msv"><img id="h366ovpo0omfxt9msv" src="https://cdn.durable.co/getty/aiMf4CuGomBSuRrE9Vr6Ib9uSBmlP7tBvHfjfuDyXJUnwA48zLcAiHpinapWRVcH.jpeg" alt="personalized products" title="personalized products" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="personalized products" data-positionx="null" data-positiony="null" data-fullwidth="false" data-mce-src="https://cdn.durable.co/getty/aiMf4CuGomBSuRrE9Vr6Ib9uSBmlP7tBvHfjfuDyXJUnwA48zLcAiHpinapWRVcH.jpeg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"><figcaption class="body-normal text-gray-500 mt-2">personalized products</figcaption></figure>Additionally, customized production can reduce waste. By manufacturing products based on exact specifications, businesses can minimize excess inventory and decrease the likelihood of unsold goods, leading to a more sustainable production model.<h3>Challenges in Implementing Customized Production</h3>Despite its benefits, customized production comes with challenges. One major hurdle is the need for a highly flexible supply chain that can adapt quickly to changing demands. Companies must invest in technology that supports real-time data analysis and agile manufacturing processes.Moreover, businesses need to ensure that their workforce is adequately trained to handle the complexities of customized production. This might involve upskilling employees to use advanced machinery or software tools designed for bespoke manufacturing.<figure id="figure-3su3gn3dskmfxt9ty8"><img id="3su3gn3dskmfxt9ty8" src="https://cdn.durable.co/getty/142lYC8QVd9P0q6L6lTkataCPVHzbxJWdY8L69kT0E0vxe5yFDPwpXkLbb9LHHhR.jpeg" alt="bespoke manufacturing" title="bespoke manufacturing" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="bespoke manufacturing" data-positionx="null" data-positiony="null" data-fullwidth="false" data-mce-src="https://cdn.durable.co/getty/142lYC8QVd9P0q6L6lTkataCPVHzbxJWdY8L69kT0E0vxe5yFDPwpXkLbb9LHHhR.jpeg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"><figcaption class="body-normal text-gray-500 mt-2">bespoke manufacturing</figcaption></figure><h3>The Role of Technology in Customized Production</h3>Technology plays a crucial role in the success of customized production. Tools such as 3D printing, computer-aided design (CAD), and artificial intelligence (AI) have made it easier for companies to offer personalized products at scale. These technologies help streamline the production process, reduce costs, and improve precision.Furthermore, digital platforms allow customers to engage directly with manufacturers, providing inputs and feedback during the design phase. This level of interaction not only enhances customer satisfaction but also improves the quality and functionality of the final product.<h3>Looking Ahead: The Future of Customized Production</h3>The trend toward customized production shows no signs of slowing down. As consumer demand for personalized experiences continues to grow, companies will need to adopt innovative approaches to remain competitive. Embracing customization is not just about meeting current demands but also about preparing for a future where personalization becomes the norm.Ultimately, separating fact from fiction in customized production will empower businesses to make informed decisions, ensuring they remain at the forefront of this evolving landscape.<h3>Start Enhancing Your Products Today​</h3>If you’re ready to upgrade to aluminum die casting parts that deliver long-lasting durability and peak performance, Shenzhen Sunmy Hardware Co.,Ltd. is your trusted partner. We serve global clients—from small businesses to Fortune 500 companies—with timely delivery (average lead time: 2–4 weeks for prototypes, 4–6 weeks for mass production) and competitive pricing.​Explore our full range of services:​<ul><li>Aluminum die casting parts supplier​ </li><li>OEM machining parts​ </li><li>Custom lathe parts manufacturer​ </li><li>Injection molding solutions​</li></ul>Visit our website at <a data-mce-href="sunmyhardware.com" href="sunmyhardware.com">sunmyhardware.com</a> to submit your project details, download our catalog, or contact our engineering team. Let’s build parts that outperform expectations—together.​Shenzhen Sunmy Hardware Co.,Ltd. – Precision in Every Cast, Durability in Every Part.

Customized Production: Separating Fact from Fiction

In today’s fast-paced manufacturing landscape, industries ranging from automotive to electronics demand components that balance durability, precision, and cost-effectiveness. Among the most reliable solutions to meet these needs is aluminum die casting—a process that transforms molten aluminum into high-performance parts tailored to strict specifications. For businesses seeking to elevate their end products, partnering with a trusted aluminum die casting parts supplier is critical. As a leading 工贸 (industry-trade) integrated foreign trade company based in Shenzhen, China, Shenzhen Sunmy Hardware Co.,Ltd. (established in 2016) specializes in delivering custom aluminum die casting parts and comprehensive machining solutions that enhance both durability and performance.<h3>Why Aluminum Die Casting Boosts Durability &amp; Performance</h3>Aluminum’s inherent properties—combined with advanced die casting techniques—make it a superior choice for high-demand applications:<figure id="figure-vu8nsecynmfwrwud6"><img id="vu8nsecynmfwrwud6" src="https://cdn.durable.co/blocks/2cDfiU9whuBMBLXOU7lU5XPvFldOPu6X9VQkRCEdKfnA80UNfRO9LyVWOHptVaTx.png" alt="" title="" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/2cDfiU9whuBMBLXOU7lU5XPvFldOPu6X9VQkRCEdKfnA80UNfRO9LyVWOHptVaTx.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>1.Exceptional Strength-to-Weight Ratio: Aluminum die casting parts are 30% lighter than steel equivalents while maintaining impressive tensile strength, reducing wear on assembled products and improving energy efficiency (critical for automotive components customization). 2.Corrosion Resistance: Aluminum forms a natural oxide layer, eliminating the need for extra coatings in many environments. This extends part lifespan, especially for outdoor or industrial use cases (e.g., industrial parts supplier applications). 3.Precision &amp; Consistency: Modern die casting processes (paired with our CNC machining service) achieve tight tolerances (up to ±0.005mm), ensuring parts fit seamlessly into complex assemblies. This consistency minimizes failure risks in high-stress scenarios, such as precision machining for medical equipment parts. 4.Design Flexibility: Unlike traditional manufacturing, aluminum die casting supports intricate geometries—from thin walls to complex cavities. This allows engineers to optimize part design for performance without compromising durability, a key advantage for custom electronic components manufacturer projects.<h3>Sunmy Hardware: Your Partner for High-Performance Aluminum Die Casting</h3>At Shenzhen Sunmy Hardware Co.,Ltd., we don’t just supply aluminum die casting parts—we deliver end-to-end solutions tailored to your unique needs. Our strength lies in:1. Comprehensive Production EcosystemWe boast a full suite of manufacturing capabilities to support every stage of your project:<ul><li>Casting: High-pressure aluminum die casting for mass-produced parts. </li><li>Machining: Advanced CNC machining service for post-casting precision (ideal for custom aluminum machining parts for electronics). </li></ul><figure id="figure-m6ke75gpsmfwry59u"><img id="m6ke75gpsmfwry59u" src="https://cdn.durable.co/blocks/305DTiiMOL5KaCAd5cesJ9fiIOAANE09NV1PddWoXe5AJd5GBlgwUnc7oaHqUy3D.png" alt="" title="" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/305DTiiMOL5KaCAd5cesJ9fiIOAANE09NV1PddWoXe5AJd5GBlgwUnc7oaHqUy3D.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure><ul><li>Lathe &amp; Stamping: Specialized in custom lathe parts according to drawing and stamping service for stainless steel brackets—ensuring compatibility with your existing designs. </li><li>Injection Molding: Complementary injection molding solutions for plastic parts and injection molding for industrial components—enabling one-stop sourcing for multi-material assemblies.</li></ul><span style="font-family: inherit; font-size: calc(18px * var(--body-fontSize, 1)); font-style: var(--body-fontStyle, normal);" data-mce-style="font-family: inherit; font-size: calc(18px * var(--body-fontSize, 1)); font-style: var(--body-fontStyle, normal);">2. Industry-Leading Customization ExpertiseAs a top custom parts manufacturer in China, we thrive on turning complex requirements into reality. Whether you need USA custom hardware parts (compliant with ANSI/ASME standards), custom metal parts for harsh environments, or custom spare parts for legacy equipment, our team works closely with you to:<ul><li>Analyze your drawings, samples, or performance goals. </li><li>Optimize designs for die casting feasibility (reducing material waste and cost). </li><li>Conduct prototype testing to validate durability and performance.</li></ul>3. Rigorous Quality ControlDurability starts with quality. Our processes include:<ul><li>Material inspection (using high-purity aluminum alloys like ADC12 and A380). </li><li>In-line testing (dimensional checks, pressure testing for leak-prone parts). </li><li>Post-production audits (salt spray testing for corrosion resistance, tensile strength analysis).</li></ul>This commitment ensures our parts meet ISO 9001 and IATF 16949 standards—critical for automotive components customization and precision plastic components used in medical devices.<h3>Real-World Applications: Where Our Aluminum Die Casting Shines</h3><figure id="figure-w552vsgvmmfwrzat7"><img id="w552vsgvmmfwrzat7" src="https://cdn.durable.co/blocks/24Wqk2MPwNpQILofN1CEJh9dJkfQ8EfRIc3VTSOxk8b155oEc45vcSzEvBCujobP.png" alt="" title="" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/24Wqk2MPwNpQILofN1CEJh9dJkfQ8EfRIc3VTSOxk8b155oEc45vcSzEvBCujobP.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>Our parts enhance durability and performance across industries:<ul><li>Automotive: Lightweight die casting brackets (reducing vehicle weight by 15%) and heat sinks (improving engine cooling efficiency). </li><li>Electronics: Custom aluminum machining parts for electronics (e.g., LED housing, server chassis) that resist thermal expansion and electromagnetic interference. </li><li>Medical: Precision machining for medical equipment parts (e.g., diagnostic device enclosures) that meet biocompatibility and sterilization requirements. </li><li>Industrial: Heavy-duty die casting gears and housings for machinery—withstand 10,000+ hours of continuous operation.</li></ul><h3>Start Enhancing Your Products Today</h3>If you’re ready to upgrade to aluminum die casting parts that deliver long-lasting durability and peak performance, Shenzhen Sunmy Hardware Co.,Ltd. is your trusted partner. We serve global clients—from small businesses to Fortune 500 companies—with timely delivery (average lead time: 2–4 weeks for prototypes, 4–6 weeks for mass production) and competitive pricing.Explore our full range of services:<ul><li>Aluminum die casting parts supplier </li><li>OEM machining parts </li><li>Custom lathe parts manufacturer </li><li>Injection molding solutions</li></ul>Visit our website at <a data-mce-href="sunmyhardware.com" href="sunmyhardware.com">sunmyhardware.com </a>to submit your project details, download our catalog, or contact our engineering team. Let’s build parts that outperform expectations—together. Shenzhen Sunmy Hardware Co.,Ltd. – Precision in Every Cast, Durability in Every Part. &nbsp;

Enhance Durability and Performance with Aluminum Die Casting Parts

3D Render: Modern Manufacturing Plant with Advanced Robotic Arms Operating on an Assembly Line with Electronic Components Moving on Conveyor Belts. Elevated Top Angle Shot Of Advanced Facility.

In the dynamic world of manufacturing, sheet metal stamping stands as a cornerstone process, widely utilized across diverse industries such as automotive, electronics, and aerospace. At Shenzhen Sunmy Hardware Co.,Ltd., since our establishment in 2016, we have been at the forefront of this field, offering comprehensive casting, lathe, machining, stamping, and injection molding services. Our expertise in custom - manufacturing parts according to clients' precise drawings and samples has made us a trusted name in the industry. However, even with our advanced capabilities, we often encounter common design mistakes in sheet metal stamping that can lead to inefficiencies, increased costs, and sub - optimal product quality. In this blog, we'll explore five of these mistakes and how to avoid them, while also taking a look at the future trends in the industry.​<h3>1. Neglecting Bend Allowance​</h3>One of the most fundamental yet frequently overlooked aspects in sheet metal stamping design is bend allowance. When a sheet metal is bent, the outer layer stretches, and the inner layer compresses. Failing to account for this change in length can result in parts with incorrect dimensions. For example, if you're designing a bracket with multiple bends, miscalculating the bend allowance can cause the bracket to not fit properly in its intended assembly.​<figure id="figure-ydjn5x52slmfv4n3l9"><img id="ydjn5x52slmfv4n3l9" src="https://cdn.durable.co/blocks/21ZZD7CCAtGEFRsvdovasdnmOVQhZG3FzsuwKYpOalfHyPWw1i5nxPveWZpL6yvy.png" alt="Bending calculation principle" title="Bending calculation principle" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: undefined undefined;" data-corners="default" data-aspect="16:9" data-caption="Bending calculation principle" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/21ZZD7CCAtGEFRsvdovasdnmOVQhZG3FzsuwKYpOalfHyPWw1i5nxPveWZpL6yvy.png" data-mce-style="aspect-ratio: 16/9; object-position: undefined undefined;"><figcaption class="body-normal text-gray-500 mt-2">Bending calculation principle</figcaption></figure>Solution: Use established formulas or software tools to accurately calculate the bend allowance based on the material type, thickness, and bend radius. At Sunmy Hardware, our experienced engineers are well - versed in these calculations and can provide design for manufacturability (DFM) advice to ensure your designs are production - ready.​<h3>2. Incorrect Material Selection​</h3>The choice of material in sheet metal stamping is crucial. Different materials have varying properties such as strength, ductility, and corrosion resistance. Using the wrong material can lead to parts that are either too brittle and prone to cracking during stamping or lack the necessary durability for their intended application. For instance, using a low - grade steel in an outdoor application where corrosion resistance is required will result in a short - lived product.​<figure id="figure-jjj7plnphmfv4p9ij"><img id="jjj7plnphmfv4p9ij" src="https://cdn.durable.co/blocks/e55LSRH4ichEKFtXMQWVvBax7j8E98rpYi8emD6FH0IVsQao1T0uR8GaQDWRv26u.png" alt="Comparing material properties" title="Comparing material properties" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="Comparing material properties" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/e55LSRH4ichEKFtXMQWVvBax7j8E98rpYi8emD6FH0IVsQao1T0uR8GaQDWRv26u.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"><figcaption class="body-normal text-gray-500 mt-2">Comparing material properties</figcaption></figure>Solution: Consider the end - use of the part, environmental factors, and mechanical requirements when selecting a material. Our company offers a wide range of materials, including aluminum, stainless steel, and various grades of carbon steel, and can guide you in making the right choice.​<h3>3. Ignoring Tolerance Requirements​</h3>Tolerances in sheet metal stamping refer to the acceptable deviation from the nominal dimensions of a part. Setting overly tight tolerances on non - critical features can significantly increase production costs, as it requires more precise and often more expensive manufacturing processes. On the other hand, setting tolerances too loose can lead to parts that do not meet the required quality standards.​<figure id="figure-8ypw8evq3mfv4tkvo"><img id="8ypw8evq3mfv4tkvo" src="https://cdn.durable.co/blocks/1e8crjf86533z4uvscpOhvWxialjek0AtwBz1Y63X0D2mwibk0YT14KHasDAQxE9.png" alt="tolerance marking standards" title="tolerance marking standards" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="tolerance marking standards" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/1e8crjf86533z4uvscpOhvWxialjek0AtwBz1Y63X0D2mwibk0YT14KHasDAQxE9.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"><figcaption class="body-normal text-gray-500 mt-2">tolerance marking standards</figcaption></figure>Solution: Clearly define the critical and non - critical dimensions of your part and set appropriate tolerances accordingly. Our state - of - the - art stamping equipment and skilled technicians are capable of achieving tight tolerances when necessary, while also optimizing the production process for cost - effectiveness.​<h3>4. Poor Hole Placement and Feature Layout​</h3>The location of holes, slots, and other features on a sheet metal part can greatly impact the stamping process. Placing holes too close to bends or edges can cause the material to deform during stamping, resulting in a poor - quality part. Additionally, an inefficient layout of features can lead to increased material waste.​<figure id="figure-5goaheyk7cmfv4uyzd"><img id="5goaheyk7cmfv4uyzd" src="https://cdn.durable.co/blocks/109Z2rwytaIJtFDisq9XgQ3Oyasx6AFlkwDAXPltZdDqekvHpFkXXzqoQTIlvmcP.png" alt="The differences in layout before and after optimization" title="The differences in layout before and after optimization" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="The differences in layout before and after optimization" data-positionx="null" data-positiony="null" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/109Z2rwytaIJtFDisq9XgQ3Oyasx6AFlkwDAXPltZdDqekvHpFkXXzqoQTIlvmcP.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"><figcaption class="body-normal text-gray-500 mt-2">The differences in layout before and after optimization</figcaption></figure>Solution: Follow industry - recommended guidelines for hole placement, such as maintaining a minimum distance from edges and bends. Our design team can assist in optimizing the layout of features to minimize material waste and ensure smooth stamping operations.​<h3>5. Overlooking Welding and Assembly Considerations​</h3>If your sheet metal part is going to be welded or assembled with other components, it's essential to consider these processes during the design stage. Poorly designed weld joints can weaken the structure of the part, and improper alignment features can make assembly difficult and time - consuming.​<figure id="figure-ftfb1tukkamfv4wqu7"><img id="ftfb1tukkamfv4wqu7" src="https://cdn.durable.co/blocks/2bZRybDn6fXyfExj8aOcscyNSQMHl1AlT9tzJDIi7oIsiHk49QebUETREvhBpVnj.png" alt="Professional welding joint design" title="Professional welding joint design" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="Professional welding joint design" data-positionX="undefined" data-positionY="undefined" data-fullWidth="false"/><figcaption class="body-normal text-gray-500 mt-2">Professional welding joint design</figcaption></figure> Solution: Design parts with clear and accessible weld joints, and incorporate alignment features such as tabs or notches. Our team has extensive experience in designing parts for seamless welding and assembly, and can provide valuable insights to streamline these processes.​<h3>Future Trends in Sheet Metal Stamping​</h3>The sheet metal stamping industry is on the cusp of significant transformation, driven by technological advancements and changing market demands. Here are some trends that we anticipate will shape the future of the industry:​Automation and Robotics​Automation and robotics are increasingly being integrated into sheet metal stamping processes. Automated stamping presses can operate with high precision and speed, reducing human error and increasing productivity. Robots are also being used for tasks such as material handling, loading, and unloading, further streamlining the production line.​Digitalization and Simulation​Digital technologies are revolutionizing the design and manufacturing process. Designers can now use advanced simulation software to model the stamping process before production, allowing them to identify and correct potential issues early on. This not only reduces the need for costly physical prototypes but also speeds up the time - to - market.​Sustainable Manufacturing​As environmental concerns continue to grow, there is a greater emphasis on sustainable manufacturing practices in the sheet metal stamping industry. This includes using recycled materials, reducing energy consumption in the production process, and minimizing waste.​At Shenzhen Sunmy Hardware Co.,Ltd., we are committed to staying at the forefront of these trends, leveraging our expertise and advanced manufacturing capabilities to provide our clients with high - quality, cost - effective sheet metal stamping solutions. Whether you're looking for custom - designed parts or need assistance with optimizing your existing designs, our team is here to help. Visit our website at <a data-mce-href="sunmyhardware.com" href="sunmyhardware.com">sunmyhardware.com</a> to learn more about our services or contact us directly to discuss your project requirements.​

Mastering Sheet Metal Stamping Design: Avoid These 5 Costly Mistakes

When it comes to manufacturing high-quality housing components—whether for electronics, automotive parts, or industrial equipment—choosing the right production process is a make-or-break decision. Two of the most widely used methods for housing components are die casting and injection molding, but each excels in specific scenarios. As a leading Shenzhen-based 工贸 (industry-trade integrated) foreign trade company with over 8 years of expertise, Shenzhen Sunmy Hardware Co.,Ltd. (visit us at <a data-mce-href="sunmyhardware.com" href="sunmyhardware.com">sunmyhardware.com</a>) has helped hundreds of global clients navigate this choice. With our full-suite production capabilities—including Casting, Lathe, Machining, Stamping, and Injection Molding—and strong R&amp;D team, we’ve refined a framework to help you select the optimal process for your housing needs.<h3>1. First: Understand the Core Difference Between Die Casting and Injection Molding</h3>Before diving into selection criteria, let’s clarify the fundamental distinction between the two processes—this will eliminate confusion as you evaluate your project:<ul><li>Die Casting: A metal-forming process where molten non-ferrous metals (e.g., aluminum, zinc, magnesium) are forced under high pressure into a steel mold (called a “die”). Once cooled, the metal part is ejected, ready for finishing (e.g., polishing, coating). It’s ideal for high-strength, heat-resistant housing components. </li><li>Injection Molding: A plastic-forming process where molten thermoplastics (e.g., ABS, PC, PP) are injected at high pressure into a custom mold. After cooling and solidification, the plastic part is removed. It’s favored for complex shapes, lightweight designs, and cost-effective high-volume production.</li></ul><figure id="figure-qpf2h8k0tmmftu53c7"><img id="qpf2h8k0tmmftu53c7" src="https://cdn.durable.co/blocks/bkPBJcrll2saCgaUyia8CG7JSKuLR38eqyCO7o1IlUjbVCtG7NQry3xNDxEtDuuu.png" alt="Key Takeaway: Die casting = metal strength; Injection molding = plastic complexity" title="Key Takeaway: Die casting = metal strength; Injection molding = plastic complexity" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 1/1; object-position: 45% 40%;" data-corners="default" data-aspect="1:1" data-caption="Die Casting (Metal Housing) Injection Molding (Plastic Housing)" data-positionx="45%" data-positiony="40%" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/bkPBJcrll2saCgaUyia8CG7JSKuLR38eqyCO7o1IlUjbVCtG7NQry3xNDxEtDuuu.png" data-mce-style="aspect-ratio: 1/1; object-position: 45% 40%;"><figcaption class="body-normal text-gray-500 mt-2">Die Casting (Metal Housing) Injection Molding (Plastic Housing)</figcaption></figure><h3>2. Key Criteria to Guide Your Choice</h3>At Sunmy Hardware, we tailor our recommendations to your project’s unique requirements. Below are the 5 critical factors we use to help clients decide between die casting and injection molding for housing components:A. Material Requirements: Metal vs. PlasticThe first question to ask is: Does your housing component need to be metal or plastic? This often narrows down your options immediately:<ul><li>Choose Die Casting if: Your housing needs high structural strength (e.g., to withstand impacts or heavy loads), excellent heat dissipation (critical for electronics like LED drivers or automotive engine parts), or corrosion resistance (e.g., outdoor equipment). Common die-cast metals for housings include: </li><li>Aluminum: Lightweight, strong, and cost-effective—perfect for consumer electronics (e.g., laptop casings) or automotive housings. </li><li>Zinc: High precision and excellent for small, intricate housings (e.g., smartphone charging port enclosures). </li><li>Magnesium: The lightest die-cast metal, ideal for aerospace or portable device housings where weight is a priority.</li></ul>Choose Injection Molding if:Your housing prioritizes lightweight design, complex geometries (e.g., internal ribs, snap-fits, or threaded holes), or flexibility (e.g., soft-touch grips for tools). Plastics also offer superior insulation (great for electrical housings) and a wide range of color/finish options (no need for post-production painting). Popular injection-molded plastics for housings include:<ul><li>ABS: Impact-resistant and easy to machine—used in TV casings or toy housings. </li><li>PC (Polycarbonate): Heat-resistant and transparent—ideal for LED light housings or safety goggles. </li><li>PP (Polypropylene): Chemical-resistant—suited for medical device housings or outdoor gear.</li></ul><figure id="figure-ln7cl6cemmmftut68q"><img id="ln7cl6cemmmftut68q" src="https://cdn.durable.co/blocks/35JKAhFvN4eVBGnLoSUNAhzn6sKZ1HZCeDkeIgCBGiatxsvhXVCJvzcmCrKagVYj.png" alt="Material Selection Guide for Housing Components" title="Material Selection Guide for Housing Components" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 1/1; object-position: 50% 35%;" data-corners="default" data-aspect="1:1" data-caption="Material Selection Guide for Housing Components" data-positionX="50%" data-positionY="35%" data-fullWidth="false"/><figcaption class="body-normal text-gray-500 mt-2">Material Selection Guide for Housing Components</figcaption></figure>B. Production Volume: Low, Medium, or High?Both processes have different cost structures, so production volume plays a major role in affordability:Die Casting: The initial cost of creating steel dies is higher (due to the metal mold’s complexity and durability). However, die casting excels at high-volume production (10,000+ units). Once the die is made, per-unit costs drop significantly—making it cost-effective for long runs (e.g., mass-produced automotive sensor housings). Injection Molding: Mold costs are lower than die casting (especially for simple designs), and it’s efficient for medium-to-high volumes (5,000+ units). For low-volume projects (e.g., prototype housings or custom medical devices), injection molding is often more budget-friendly than die casting, as the lower mold cost offsets higher per-unit plastic costs.Pro Tip from Sunmy: If you need a small batch of prototype housings (10–100 units) to test design feasibility, our machining capabilities can bridge the gap—we can create custom metal or plastic prototypes before scaling to die casting or injection molding.C. Design Complexity: Simple vs. IntricateThe complexity of your housing’s design will also influence your choice:Die Casting: Best for simple-to-moderately complex shapes with uniform wall thickness (3–5mm is optimal). While modern die-casting technology can handle some intricate details (e.g., thin walls or small holes), it’s limited by the metal’s flow properties—too many undercuts or sharp angles may cause defects (e.g., air bubbles or incomplete filling). Injection Molding: The clear winner for highly complex designs. Plastics flow more easily than molten metal, so injection molds can accommodate undercuts, internal cavities, thin walls (as low as 0.5mm), and even integrated features (e.g., hinges or gaskets). This reduces the need for post-production assembly—saving time and cost. For example, we recently helped a client design a one-piece plastic housing for a smart thermostat that included built-in wire channels and snap-fits, eliminating 3 separate assembly steps.D. Cost: Upfront Investment vs. Long-Term SavingsCost is always a priority, but it’s important to look beyond just per-unit prices—consider upfront mold costs and total lifecycle expenses:<figure id="figure-4v2qtbc795mftrb72q"><img id="4v2qtbc795mftrb72q" src="https://cdn.durable.co/blocks/197aY8WJYEfcqwxmorqZzAl9RzKolNhDj8LRDP4iRCGSuBjBONpNoPAu0CX8DSSj.jpg" alt="" title="" class="object-cover bg-gray-100 rounded-lg md:rounded-xl lg:rounded-2xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/197aY8WJYEfcqwxmorqZzAl9RzKolNhDj8LRDP4iRCGSuBjBONpNoPAu0CX8DSSj.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>At Sunmy Hardware, we offer transparent cost quotes tailored to your volume. For example, if you need 20,000 aluminum housings for industrial sensors, die casting may be more cost-effective in the long run. If you need 5,000 plastic housings for a new consumer gadget, injection molding will likely save you money upfront.E. Lead Time: How Fast Do You Need Your Housings?Lead time is critical for meeting product launch deadlines. Here’s how the two processes compare:<ul><li>Die Casting: Mold production takes longer (4–8 weeks) because steel dies require precision machining and heat treatment to withstand high temperatures and pressure. Once the die is ready, production runs are fast (1–2 weeks for 10k units). </li><li>Injection Molding: Mold production is faster (2–4 weeks) for standard plastic molds (though complex molds may take longer). Production runs are also quick—we can deliver 10k plastic housings in 1–2 weeks once the mold is approved.</li></ul> Sunmy Advantage: Our in-house mold design and production team (no outsourcing!) speeds up lead times by 20–30% compared to competitors. Whether you need die-cast metal or injection-molded plastic housings, we can align with your launch timeline.<h3>3. When to Partner with a Custom Manufacturing Expert Like Sunmy Hardware</h3>Choosing between die casting and injection molding isn’t always black and white. For example:<ul><li>What if you need a housing that’s metal for strength but has plastic inserts for insulation?</li><li>What if your design is complex, but you need high-volume production at a low cost?</li></ul>This is where Sunmy Hardware’s expertise shines. As a 工贸一体 (industry-trade integrated) company, we don’t just manufacture—we collaborate with you to optimize your design for cost, performance, and scalability. Our capabilities include:<ul><li>Custom Mold Design: We create dies and molds tailored to your 2D/3D drawings or physical samples (send us your design today at gavin@sunmyhardware.com). </li><li>Hybrid Solutions: We combine processes (e.g., die casting + injection molding inserts) to meet unique needs. </li><li>End-to-End Service: From prototyping and production to finishing (painting, anodizing, plating) and quality control, we handle every step—so you don’t have to manage multiple suppliers.</li></ul>We’ve helped clients across industries:<ul><li>An automotive parts maker switch from plastic to aluminum die-cast housings for better heat resistance. </li><li>A consumer electronics brand reduce costs by 15% by optimizing their injection-molded housing design. A medical device company launch a new product on time with our fast prototype-to-production workflow.</li></ul><h3>Final Checklist: Which Process Is Right for Your Housing Component? Use this quick checklist to summarize your decision:</h3>✅ If your housing needs: Metal, high strength/heat resistance, high volume (10k+ units) → Choose Die Casting. ✅ If your housing needs: Plastic, complex design, medium-to-high volume (5k+ units) → Choose Injection Molding. ✅ If you’re unsure: Contact Sunmy Hardware. Send us your drawings, samples, or project requirements, and our engineers will provide a free, no-obligation recommendation.At Shenzhen Sunmy Hardware Co.,Ltd., we’re more than a manufacturer—we’re your partner in creating high-quality, custom housing components. Visit<a data-mce-href="sunmyhardware.com" href="sunmyhardware.com"> sunmyhardware.com</a> to explore our case studies, view our production facilities, or request a quote. Let’s turn your design into a reality.

How to Choose Between Die Casting and Injection Molding for Your Housing Component?

SUNMY HARDWARE

 Our company is a foreign trade company established in Shenzhen in 2016, the English name of the company is Shenzhen Sunmy Hardware Co.,  Ltd..  Our company has been focusing on manufacturing customized parts and products, now the company team is very strong, very good at customized production according to customer's product or part needs and drawings or samples, because the company has extremely strong development capacity and has these Casting/Lathe/Machining/Stamping/Injection Molding perfect production system, can serve the needs of different customers at home and abroad 

Blog

5 Costly DFM Mistakes in Sheet Metal Stamping Design You’...

A Beginner's Guide to Injection Molding for Precision Ind...

Customized Production: Separating Fact from Fiction

Enhance Durability and Performance with Aluminum Die Cast...

Mastering Sheet Metal Stamping Design: Avoid These 5 Cost...

How to Choose Between Die Casting and Injection Molding f...