In-house forging die manufacturing refers to the process of designing, machining, and maintaining forging dies within a Flexico’s own facility rather than outsourcing to external suppliers. This approach offers greater control over quality, lead times, and costs, making it ideal for high-volume or precision forging operations.
Key Benefits of In-House Die Manufacturing
- Reduced Lead Times – Eliminates reliance on external suppliers, speeding up production cycles.
- Cost Savings – Lower long-term costs by avoiding mark-ups from third-party die makers.
- Quality Control – Direct oversight of die material, heat treatment, and machining ensures consistency.
- Customization & Flexibility – Easier to modify dies for design changes or new product development.
- Faster Maintenance & Repair – Immediate die rework reduces downtime in forging operations.
The In-House Forging Die Manufacturing Process
- Design & Engineering – Use CAD/CAM software (e.g., SolidWorks, AutoCAD) to design dies based on part specifications.Finite Element Analysis (FEA) simulations optimize die life and performance.
- Material Selection – Common die materials: Tool steels (H13, D2), tungsten carbide, or maraging steel for high-wear resistance.
- Die Machining – CNC milling, EDM (Electrical Discharge Machining), and grinding for precision shaping.High-speed machining (HSM) for complex geometries.
- Testing & Validation –Trial forging runs to check for defects (flash, underfill) and adjust as needed.
- Maintenance & Repair –Regular inspections, welding (for cracks), and resurfacing to extend die life.
- NDA Adherance –An in-house forging die manufacturing and testing facility significantly enhances NDA adherence by minimizing external exposure.
