Joincast FAQ
Do you only provide die casting, or can you handle complete part finishing?
JoinCast operates as a vertically integrated manufacturer with all processes under one roof at our 9,900 m² facility. Components progress from mold engineering and die casting through CNC machining, polishing, shot blasting, surface treatment, TPR insert molding, printing, and quality inspection without leaving our facility.
This eliminates coordination across multiple suppliers and reduces your total landed cost.
What industries and applications does JoinCast specialize in?
We serve marine components requiring corrosion-resistant ADC-3 / A383 alloy, pneumatic tool housings and mechanisms, agricultural machinery components for outdoor durability, LED lighting heat sinks optimized for thermal management, and medical equipment parts requiring tight tolerances.
Our die casting machines (135T-900T) and precision CNC capabilities handle parts from 10g to 3kg+ across these demanding applications.
What certifications and quality standards does JoinCast maintain?
JoinCast is ISO 9001:2015 certified with comprehensive quality management systems covering all production processes. Our 10-member quality team uses 2 Mitutoyo CMM systems, Keyence 3D scanning, material spectrometry, salt spray testing, and surface roughness verification.
We provide complete documentation including first article inspection reports, material certifications, dimensional reports, and traceability records required for medical equipment and automotive applications.
Can your team communicate effectively in English for engineering and commercial discussions?
Our sales, engineering, and quality teams can communicate in English, Japanese and Chinese for all customer interactions including technical discussions, drawing reviews, and project coordination. We provide English-language quotations, inspection reports, and documentation.
Taiwan’s export-focused manufacturing culture means our staff has extensive experience working with North American and European customers. Video conferences can be scheduled to accommodate Western time zones.
How do you protect customer intellectual property and proprietary designs?
All customer designs, CAD files, and proprietary information are protected under non-disclosure agreements standard in our contracts. Molds and fixtures remain secured within our facility with access limited to assigned production teams.
Taiwan’s strong intellectual property legal framework and our relationships with Fortune 500 clients reflect our commitment to confidentiality. We never produce similar parts for competitors without explicit customer permission.
What's the process for getting a quote and starting a new project with JoinCast?
Submit your CAD files (STEP, IGES formats) and 2D drawings with specifications through our contact form or email. Our engineering team provides quotations within 5-7 business days including DFM feedback, recommended process flow, tooling costs, piece prices at different volumes, and estimated timelines.
After quote approval, we proceed with mold design review, simulation, fabrication, sampling, and your approval before production begins.
Who owns the die casting molds - JoinCast or the customer?
Mold ownership is negotiable and specified in your contract. Regardless of ownership, all molds remain stored at our Changhua, Taiwan facility for the life of your production program.
Can your mold engineering team provide design for manufacturing (DFM) feedback on my part design?
Yes, our 9-person mold engineering team reviews customer CAD files during the quoting phase and provides DFM recommendations including draft angle optimization, wall thickness uniformity, gate placement for minimal visible marks, and geometry modifications to improve castability.
We use mold flow simulation to identify potential defects before mold fabrication begins.
What happens if I need to modify the mold after production has started?
Our in-house mold repair and adjustment team can implement modifications for minor changes like dimension adjustments or texture modifications.
Major geometry changes requiring welding and re-machining are also possible but could impact production schedules. Because all molds remain at our Taiwan facility, we avoid the coordination delays typical when molds are stored at third-party tooling shops.
How long does mold design and fabrication typically take?
Mold manufacturing time is directly proportional to the size, tonnage, and complexity of the machine. A production schedule will be provided after the contract is signed. It is not available during the quotation stage.
Do you perform mold flow simulation before cutting steel?
Yes, our mold design team uses simulation software to predict fill patterns, identify potential porosity locations, optimize gate and runner sizing, and validate cooling channel effectiveness.
Simulation results inform gate placement to minimize visible marks on cosmetic surfaces and prevent defects in critical functional areas. We share simulation reports with customers during mold design review.
How do you maintain molds between production runs to ensure consistent quality?
Our dedicated mold maintenance technician performs preventive maintenance including cleaning, lubrication, and inspection after each production run. Molds are stored in our climate-controlled facility with rust prevention treatment.
Before each production restart, molds undergo setup verification and first article inspection to confirm dimensions match previous runs. Maintenance records are documented in our ISO 9001:2015 system.
How do you handle mold design for parts requiring tight tolerances on critical dimensions?
Our mold designers account for aluminum shrinkage rates (typically 0.5-0.7%) when programming cavity dimensions, with tighter compensation for critical features. For LED lighting components requiring precise optical alignment or medical equipment parts with assembly tolerances, we build adjustment capability into mold design.
First article inspection with CMM verification confirms dimensions before full production, with mold adjustments made if needed.
How do I determine which die casting machine tonnage my part requires?
Machine tonnage requirements depend on your part’s projected surface area (the 2D silhouette of the part perpendicular to mold opening direction). As a rough guide, parts under 150mm typically fit our 135T-250T machines, parts 150-350mm use 250T-420T machines, and large components above 350mm require our 900T machine.
Our mold engineering team calculates precise tonnage requirements during quoting based on your CAD files and projection area.
What's the difference between ADC-12 / A360 and ADC-3 / A383 aluminum alloys, and which should I specify?
ADC-12 / A360 (equivalent to ADC-3 / A383) offers excellent castability and represents 82% of our production, ideal for pneumatic tools, agricultural machinery, and LED lighting where corrosion resistance is secondary. It is the most commonly use material for die casting.
ADC-3 / A383 (ADC-12 / A360) provides enhanced corrosion resistance for marine components, boat hardware, and outdoor applications exposed to saltwater or harsh environments, though it costs approximately 15-20% more than ADC-12 / A360 and has lower fluidity than ADC-12 / A360.
What's your minimum order quantity for die cast aluminum parts?
MOQ depends on part complexity and size. Simple single-cavity parts from our 135T-420T machines have 2,000-piece minimums, while complex multi-cavity molds or large castings from our 900T machine require 1,000 piece minimums to justify tooling investment.
How do you control porosity in critical structural areas of die castings?
Our mold flow simulation identifies potential porosity locations during mold design, allowing strategic gate placement and venting to direct porosity away from critical areas. Vacuum-assisted casting and optimized injection parameters minimize gas entrapment.
For medical equipment components or pneumatic tool pressure chambers requiring zero porosity, we specify X-ray inspection or proof pressure testing as additional verification.
What wall thickness limitations should I design for in aluminum die castings?
Minimum wall thickness is typically 2.5-4.5mm depending on part size and flow length. Walls below 1.5mm risk incomplete fill or weak sections.
Maximum wall thickness should generally not exceed 10mm due to shrinkage and porosity concerns in heavy sections. Our mold engineering team provides DFM feedback during quoting if your design includes problematic wall thickness variations.
What surface finish can I expect directly from the die casting process?
As-cast aluminum surfaces typically achieve Ra 3.2-6.3 μm depending on mold condition and part geometry. This requires polishing or shot blasting before surface coating for most applications. Cosmetic surfaces visible to end users need secondary finishing operations.
Mold texturing can create specific surface patterns, but fine surface finish requires post-casting polishing at our facility.
What quality checks happen during die casting before parts move to CNC machining?
Operators perform visual inspection for surface defects, flash, and incomplete fill on every casting. Dimensional spot checks using go/no-go gauges verify critical features at defined intervals.
Our quality team conducts periodic weight checks to confirm consistent cavity fill and samples parts for CMM verification. Defective castings are scrapped immediately rather than proceeding to expensive CNC machining operations.
How do I know whether my parts need polishing, shot blasting, or both?
Shot blasting removes surface scale and provides uniform matte finish preparation for powder coating or anodizing, while polishing creates smooth, reflective surfaces for visible components or applications requiring low friction.
Parts destined for surface coating typically need only shot blasting, whereas consumer-facing products like marine hardware or pneumatic tool housings often require polishing before coating for premium appearance.
Will shot blasting affect the dimensional accuracy of my machined features?
Shot blasting removes approximately 0.005-0.01mm of surface material, which we account for during CNC programming. Critical machined dimensions and threaded features are masked during blasting operations to preserve tolerances.
Our quality team verifies dimensions post-blasting using CMM measurement before components proceed to surface treatment or final inspection.
What's the difference between hanger, drum, and vibratory barrel shot blasting methods?
Hanger shot blasting suspends individual parts for controlled exposure, ideal for large or complex geometries requiring specific blast angles. Drum blasting tumbles high volumes of smaller parts together for efficient processing.
Vibratory grinding produced sharper edges for delicate features or thin-walled castings requiring deburring without aggressive material removal.
Can polishing remove porosity or surface defects from die castings?
Polishing removes minor surface imperfections and smooths texture but cannot eliminate subsurface porosity or deep defects. If your application requires cosmetic Class A surfaces, specify this during quoting so our mold engineering team can optimize gate placement and venting to minimize surface defects in critical areas.
Heavy polishing to remove defects can create dimensional inconsistencies.
How does in-house polishing and shot blasting reduce my lead times?
Components move directly from our 12 die casting machines to finishing operations within our 9,900 m² Taiwan facility without external shipping.
This eliminates the typical 3-5 day coordination delay when polishing is outsourced, and prevents quality control gaps between suppliers. Parts can proceed from casting to surface preparation to coating in a continuous workflow.
What surface roughness (Ra) can you achieve through polishing and shot blasting?
Shot blasting typically produces Ra 1.6-3.2 μm depending on media size and blast intensity, providing ideal tooth for powder coating adhesion. Mechanical polishing achieves Ra 0.4-0.8 μm for smooth surfaces, with mirror polishing reaching Ra 0.1-0.2 μm for premium applications.
We verify surface roughness using our 2 dedicated testers before components proceed to coating operations.
Will shot blasting damage thin-walled sections or delicate features on my castings?
Our team selects media size and blast intensity based on wall thickness and feature geometry. Thin-walled sections below 2mm receive vibratory barrel finishing rather than aggressive hanger blasting.
Delicate features like fins on LED lighting heat sinks or thin ribs on pneumatic tool housings are masked during blasting, or we use gentler tumbling methods.
What's the maximum part size your polishing and shot blasting equipment can handle?
Our hanger shot blaster accommodates parts up to 800mm from our 900T die casting machine, while drum blasting handles components up to approximately 300mm efficiently.
Polishing capacity depends on geometry, but our 8 mechanical polishing machines process parts from small pneumatic tool components to large marine hardware and agricultural machinery housings.
Can you machine features that cannot be die cast, like internal threads or tight-tolerance bores?
Yes, our 49 CNC machines handle secondary operations including threading, precision boring, tapping, and chamfering that cannot be achieved in the casting process.
All machining centers have 4th axis capability for complex angled features, and our OKUMA horizontal lathes are specifically configured for precision bore work on valve bodies and cylindrical components.
What tolerances should I specify for as-cast surfaces versus CNC machined surfaces?
As-cast surfaces typically hold ±0.1mm, while our CNC machined surfaces achieve ±0.01mm (H6-H7 tolerances) in our temperature-controlled facility.
We recommend specifying tighter tolerances only on critical mating surfaces and functional features to optimize cost, as excessive machining removes the economic advantage of die casting’s near-net-shape capability.
Do you require customers to provide CNC fixtures, or are they included in tooling costs?
Our fixture design and fabrication team develops all CNC fixtures in-house as part of the project setup. Fixture costs are separate from die casting mold costs but are included in the initial quotation.
We maintain all fixtures at our Changhua facility for the life of your project, ensuring consistent setup for repeat orders.
How do you prevent dimensional drift during high-volume CNC production runs?
Our quality team performs CMM sampling at defined intervals throughout production runs, with automatic process adjustment if measurements trend toward tolerance limits.
Temperature-controlled machining prevents thermal expansion issues, and our ISO 9001:2015 system requires statistical process control documentation for all high-volume orders to ensure consistency from first part to last.
Can you handle secondary operations like deburring, tapping, and countersinking in-house?
Yes, all secondary operations are performed within our facility. Our 8 polishing machines and 3 shot blasting systems handle deburring after casting, while tapping, countersinking, and chamfering are programmed into CNC operations.
This eliminates the quality control gaps and lead time delays that occur when these operations are outsourced to third-party machine shops.
What CNC machining capabilities do you have for large castings from your 900T die casting machine?
Our 2 Victor Taichung vertical machining centers accommodate parts up to 1300 x 600 x 610 mm with ±0.01mm accuracy. These machines have reinforced beds and temperature monitoring specifically for large aluminum castings, preventing deflection during heavy cuts.
Large parts receive additional CMM verification points to ensure dimensional accuracy across the entire casting surface.
What TPR hardness options are available for tool grips and handles?
We offer TPR durometers ranging from Shore A 40 (soft, cushioned feel) to Shore A 70 (firmer, more durable) depending on your application requirements.
Pneumatic tool handles typically use Shore A 50-60 for optimal grip comfort during extended use, while other applications may require firmer TPR for mechanical durability. We can provide samples at different harnesses for your evaluation.
How do you ensure the TPR bonds properly to the aluminum casting?
Aluminum surfaces undergo specific preparation including degreasing and primer application before TPR injection molding. The combination of mechanical interlocking (achieved through designed undercuts in the casting) and chemical adhesion creates permanent bonds that withstand tool operation stresses.
We can perform pull-testing on first articles to validate bond strength for your application.
Can you mold TPR over powder-coated or anodized aluminum surfaces?
TPR adhesion works best on bare aluminum or specifically formulated primers. Powder coating and anodizing create barrier layers that prevent proper TPR bonding.
What printing methods do you use for logos and branding on aluminum parts?
For multi-color logos or complex graphics, we can recommend laser etching or external specialized printing partners.
How durable is pad printing on parts that will be handled frequently or exposed outdoors?
Pad printing on properly prepared aluminum surfaces withstands normal handling, but high-wear areas like grip surfaces or frequently touched controls will show wear over time.
For pneumatic tools and marine hardware exposed to solvents, UV, or abrasion, we recommend printing on non-contact surfaces. UV-resistant inks are available for outdoor applications, and we can perform adhesion testing per your requirements.
Can you match specific Pantone colors for printed logos on my products?
Yes, we can match Pantone colors for pad printing, though final appearance varies slightly based on substrate color and surface texture. We recommend providing physical color samples or approved parts for matching rather than relying solely on Pantone numbers.
First article samples will be submitted for your approval before production printing begins.
What inspection reports and documentation do you provide with shipments?
Standard shipments include dimensional inspection reports with CMM data for critical features, material certification confirming aluminum alloy composition, and visual inspection checklists.
ISO 9001:2015 certification ensures all inspection records are traceable and archived.
Do you perform first article inspection (FAI) before full production runs?
Yes, our 10-member quality team conducts complete first article inspection using our 2 Mitutoyo CMM systems and Keyence 3D scanner to verify all dimensions against your drawings. FAI reports document every specified dimension, surface finish measurement, and material verification.
We submit FAI documentation and physical samples for your approval before proceeding with full production quantities.
How do you handle non-conforming parts discovered during production?
Non-conforming parts are immediately quarantined in our designated red-tag area and documented in our ISO quality management system.
All reworked parts receive 100% re-inspection before proceeding to packing.
What's the measurement uncertainty of your CMM equipment for tight-tolerance verification?
Our 2 Mitutoyo CMM systems provide measurement uncertainty of ±0.002mm under temperature-controlled conditions at our Changhua facility.
This ensures reliable verification of ±0.01mm tolerances with adequate measurement capability.
How does your 3D scanner complement traditional CMM inspection?
Our Keyence 3D scanner rapidly captures complete part geometry for comparison against CAD models, identifying deviations across entire surfaces rather than discrete measurement points.
This is particularly valuable for complex marine components or agricultural machinery castings where traditional CMM inspection would require hundreds of individual touch points. Scan data provides color-mapped deviation reports showing exactly where geometry varies from nominal.
What material testing do you perform to verify aluminum alloy specifications?
Our aluminum material spectrometer analyzes elemental composition within 60 seconds, verifying ADC-12 / A360 or ADC-3 / A383 alloy specifications before production begins. This is critical for marine components requiring ADC-3 / A383’s enhanced corrosion resistance.
Material certification documents from our ingot suppliers are verified against our spectrometer readings, and test results are included in your shipment documentation package.
Do you perform salt spray testing for marine and outdoor applications?
Yes, our salt spray tester conducts ASTM B117 corrosion resistance testing on powder-coated, liquid-coated, and anodized surfaces before production shipments.
Testing duration depends on your application requirements, typically 96-500 hours for marine components and LED lighting fixtures exposed to coastal or outdoor environments. Test coupons from each coating batch undergo evaluation, with photographic documentation of results.
Why choose die casting over extrusion for heat sink production?
Die casting allows for complex three-dimensional fin geometries that extruded profiles cannot achieve. Where extruded heat sinks are limited to uniform cross-sections, die-cast components can incorporate variable fin heights, non-linear arrangements, and integrated mounting features in a single part. This tends to improve thermal performance in applications with restricted airflow or unconventional form factors.
Die casting also eliminates secondary operations for features like boss holes and clip mounts, reducing your total component cost at production volumes.
What alloy do you recommend for heat sink applications?
ADC-12 / A360 is our standard recommendation for most heat sink and controller housing applications. It offers a good balance of thermal conductivity, castability, and cost-effectiveness for LED systems, power electronics, and industrial controllers.
For applications requiring higher thermal performance, we can work with ADC-3 or discuss alternative alloys based on your specific heat dissipation requirements and operating environment.
How do you ensure flatness tolerances on heat sink mounting surfaces?
Critical mounting surfaces undergo CNC machining after casting to achieve the flatness tolerances required for effective thermal interface contact.
Our temperature-controlled machining operations maintain dimensional stability, and CMM inspection verifies flatness to your specified tolerances before components ship. This should mean consistent thermal transfer between your heat sink and the components it serves.
Can you integrate heat sink features directly into controller housings?
Yes. Our mold engineering team can design controller enclosures with integrated heat sink fins, eliminating the need for separate thermal management components and the assembly steps that go with them.
This approach reduces part count, simplifies your supply chain, and often improves thermal performance by removing interface resistance between housing and heat sink.
What surface treatments do you offer for heat sink components?
We provide anodizing, powder coating, and chemical conversion coatings in-house. Anodizing is the most common choice for heat sinks, as it improves corrosion resistance and emissivity without significantly affecting thermal conductivity.
For controller housings requiring specific colours or enhanced environmental protection, powder coating offers a durable finish. Our team can recommend the appropriate treatment based on your application requirements and operating conditions.
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