OEM

Wax Pattern Making

1. Molten wax is injected into a metal mold, and after cooling, a wax model that perfectly matches the final part is obtained.

2. Multiple wax models can be combined into a wax assembly (similar to a tree shape), complete with a gating and riser system.

Shell Making

1. The wax model assembly is immersed in a refractory slurry (such as silica sol), then sprinkled with refractory sand, repeating layer by layer to form a multi-layered ceramic shell.

2. This ceramic shell will be the future casting cavity.

Dewaxing

The wax model with the shell is placed in a wax steaming furnace or hot water, heated to melt the inner wax model and flow out, forming a hollow ceramic shell.

Shell Firing/Baking

The hollow shell is fired at high temperature to burn off residual wax, increase strength, and remove moisture, while simultaneously completing the final shaping of the shell.

Melting & Pouring

1. Qualified metal (such as stainless steel, alloy steel, copper alloy, etc.) is melted.

2. The molten metal is poured from the gating gate into the fired ceramic shell, filling the cavity.

Cooling & Shell Removal

After the metal cools and solidifies, the outer shell is broken through methods such as vibration, water spray, or manual hammering to obtain the casting blank.

Post-Treatment

Gating gates and risers, burrs, and other imperfections are removed. Grinding, shot blasting, heat treatment, and precision machining are then performed to bring the casting to its final requirements.

Design & Planning

Contact and Confirmation: Understanding the client's product requirements, quantity, budget, and materials.

Drafting (CAD) 

Creating 2D or 3D product models and generating drawings in Computer-Aided Design (CAD) software.

CAM & Coding

CAM Programming: Importing CAD files into Computer-Aided Manufacturing (CAM) software.

G-Code Generation: Engineers set parameters such as tooling, machining paths, cutting speeds, and feed rates. The program converts these instructions into G-code that the machine tool can understand.

Setup & Prototyping

Machine Setup: Fixing the blank on the machine tool and selecting and assembling the required tools.

First Article Prototyping: Inputting the program to produce the first sample for customer verification, confirming dimensions and accuracy.

Mass Production

Batch Production: The machine automatically executes the pre-set program to manufacture large or small batches of parts.

Post-Processing & QC

Deburring/Grinding: Trimming rough edges.

Surface treatment: such as anodizing, electroplating, powder coating, polishing, etc., to enhance aesthetics and durability.

Final Quality Control (QC): Final inspection of finished products to ensure they meet specifications.

Packaging and Shipping: Delivery to the customer after packaging.

Gear forging refers to the method of heating metal raw materials to a molten state and then pressing them into shape using a mold.

This process mainly includes the following steps:

Heat treatment: 

This is the first step in gear machining, aimed at improving the material's strength and wear resistance.

Casting:

 The heat-treated metal raw material is poured into a specialized mold and solidified into a complete part through pressure casting.

Forging: 

The cast part is placed in a high-temperature forging press for repeated hammering, further shaping the metal.

Rolling: 

The forging is further adjusted in size and shape through operations such as cold drawing or hot rolling.

Machining: 

Finally, the gear undergoes precision machining, including grinding, lapping, and milling, to meet the requirements of various mechanical equipment.

Design & Preparation

1. Drawing: Engineers create 3D/2D drawings based on requirements.

2. Process Planning: Determine the processing plan and select materials.

3. Material Procurement: Procure thin metal sheets such as cold-rolled steel, stainless steel, and aluminum.

Cutting

1. Laser Cutting/CNC Punching: Use a laser or punch press to cut large sheets into blanks according to the drawing dimensions.

2. Stamping Forming: Perform blanking, punching, grooving, and stamping operations using dies.

Forming

1. Bending: Use a bending machine to bend the sheet metal to the required angle.

2. Stamping/Stretching: A stamping machine plastically deforms the sheet metal to create complex shapes.

3. Rolling/Turning: Bend the sheet metal into cylinders or arcs.

4. Riveting/Pre-riveting: Pre-press nuts, screws, etc., into holes in the sheet metal.

Joining

1. Welding: Spot welding, arc welding, laser welding, etc., connect multiple parts together.

2. Riveting: Secure parts using rivets.

Surface Treatment & Finishing

1. Deburring/Polishing: Remove burrs left from cutting and machining, and polish the surface.

2. Cleaning: Clean away oil and dust.

3. Powder Coating/Electroplating/Anodizing: Apply powder coating, paint, or electroplating to provide corrosion resistance, aesthetics, and other functions.

Assembly & Quality Control

1. Assembly: Assemble the treated parts into a complete product.

2. Inspection: Conduct rigorous quality checks on dimensions, appearance, and functionality.

Packaging & Delivery

1. Packaging: Protect finished products from damage during transportation.

2. Delivery: Deliver products to customers on time.