MES Offers Customers Megacasting Power: Now with a Bühler 4400-Ton Die Casting Press

We’re thrilled to announce a monumental leap forward in our manufacturing capabilities! We’re excited to share that one of our key suppliers in Ningbo, China, has recently adopted a state-of-the-art BUHLER 4400-ton die casting press. This strategic investment signifies a new era of possibilities for our partners and clients, particularly those in the automotive, e-mobility, and other industries demanding large, complex, and high-integrity metal components.

Understanding the BUHLER 4400-Ton Marvel: Core Function and Key Specifications

At its heart, this 4400-ton press is a cold chamber high-pressure die casting (HPDC) machine. This means molten metal, typically aluminum or magnesium alloys, is precisely ladled into a shot sleeve before being injected at extremely high speeds and pressures into a steel die cavity. Rapid solidification then forms a precisely shaped part. The “4400 tons” refers to the incredible die locking force (MAX 44,000 kN) that clamps the two halves of the mold together, preventing molten metal from flashing out during injection.

This machine is a true titan, designed for components that push the boundaries of size and complexity. Here are some of its impressive technical specifications:

• Tie-Bar Space: Around 72.8 x 72.8 inches (approx. 1850 x 1850 mm), providing ample room for large dies.
• Die Stroke (Clamping Stroke): A significant 70-80 inches (approx. 1778 – 2032 mm), allowing for efficient part ejection.
• Min-Max Die Height: A broad range of 35.4 – 82.7 inches (approx. 900 – 2100 mm), accommodating diverse die sizes.
• Ejector Force: Over 120 US Tons (approx. 1000 kN), ensuring robust part removal.
• Shot Force: Can exceed 265 US Tons (approx. 2350 kN), delivering powerful injection.
• Shot Stroke: Often 55-63 inches (approx. 1400 – 1600 mm), enabling flexible shot sizes.
• Casting Pressure (Intensification): Very high, typically 15,000 – 20,000+ psi (approx. 100-140+ MPa), for superior material density.
• Max. Casting Area: Up to an astounding 1550 – 1900+ square inches (approx. 10,000 – 12,000+ cm²).
• Injection Speed: High-performance capabilities can achieve speeds up to 8.2 m/s for rapid cavity filling.
• Shot Weight (Aluminum): Capable of producing substantial castings ranging from 114 to 180+ pounds (approx. 50-80+ kg) of aluminum.
• Machine Dimensions: These machines are truly enormous, often exceeding 600 inches (15+ meters) in length, requiring significant floor space and robust infrastructure.

Here’s a breakdown of what these massive presses enable in the automotive industry:

1. Revolutionizing Vehicle Underbody Structures: This is arguably the most significant application. Unlike smaller presses that produce individual structural nodes or smaller sub-frames, a BUHLER 4400-ton press allows for the casting of entire vehicle sections. This includes complete front underbodies, rear underbodies, or substantial portions of the central floor and chassis as one seamless piece. These single, massive castings can replace anywhere from 50 to over 100 smaller stamped, welded, and assembled components, leading to dramatic reductions in part count, manufacturing complexity, and assembly time on the production line. This paradigm shift is already being embraced by major OEMs for their latest EV platforms.
2. Integrated Battery Housings and Trays for EVs: As the electric vehicle market rapidly expands, the demand for large, complex, and structurally robust battery enclosures is paramount. A BUHLER 4400-ton press is uniquely positioned to cast entire battery trays or significant sections of these housings in a single piece. Beyond merely containing battery cells, these integrated castings contribute significantly to the vehicle’s overall structural integrity, crash performance, and thermal management. Achieving such a structure with smaller presses would necessitate numerous separate castings and extensive welding, inevitably adding weight and complexity.
3. Complex Structural Nodes and Sub-Frames: While smaller presses can certainly produce certain structural elements, a BUHLER 4400-ton machine truly excels at casting highly intricate structural nodes. These components integrate multiple functionalities, precision attachment points for suspension systems, and crucial energy absorption zones into one cohesive part, resulting in lighter, stronger, and more precise vehicle structures. Effectively solved the problem of internal porosity in the product.
4. Handling Extreme Component Dimensions and Weight: The “shot weight” (the amount of molten metal injected per shot) and the maximum “casting area” of a BUHLER 4400-ton press far exceed the capabilities of smaller machines. This allows for the production of automotive parts weighing well over 100 pounds – a feat impossible for less powerful equipment. Furthermore, the extensive tie-bar space and impressive die stroke are indispensable for accommodating the enormous dies required for these monumental components, which themselves can weigh many tons.
5. Enhanced Quality for Large-Scale Parts with BUHLER Swiss Technology Vacuum Assist: Producing large, defect-free castings presents inherent challenges related to metal flow and solidification. The immense clamping force of these presses, combined with the crucial ability to integrate advanced Swiss technology vacuum assist systems, becomes indispensable. By evacuating air from the die cavity prior to injection, porosity and trapped gases are significantly reduced, leading to superior mechanical properties. This improved quality often allows these critical structural components to undergo heat treatment, further boosting their strength and performance. While Buhler vacuum assist can benefit critical smaller parts on conventional presses, it is a true game-changer for the integrity of large structural elements. (https://vimeo.com/1105793141）

In essence, a BUHLER 4400-ton press propels automotive manufacturing beyond merely casting individual, isolated components. It enables a fundamental shift in vehicle architecture through radical parts consolidation. This directly contributes to:

• Significant Weight Reduction: Absolutely critical for maximizing EV range and overall vehicle efficiency.
• Reduced Manufacturing Complexity and Cost: Fewer parts, fewer assembly steps, optimized use of robotics, and a smaller factory footprint.
• Improved Structural Performance: A single cast part is inherently stronger and more rigid than an assembly of welded pieces.
• Faster Production Cycles for Large Parts: Despite their massive size, these integrated castings can be produced remarkably quickly compared to traditional multi-part assembly lines.

Ultimately, smaller presses are fundamentally limited to smaller, less integrated components such as certain engine blocks (though some advanced smaller presses can handle these), transmission housings, brackets, sensor housings, and various minor chassis components. They simply lack the clamping force, shot size, or platen space required to produce the monumental structural elements that are defining the next wave of automotive innovation.

The Technical Edge: Inside the BUHLER 4400-Ton Marvel

Beyond the sheer tonnage, the engineering behind this press is truly impressive. Its robust clamping unit features massive platens and tie bars designed to withstand immense forces, ensuring unwavering die stability and precision throughout the casting process.

Complementing this is a high-performance injection system, powered by a formidable hydraulic setup often utilizing accumulators to deliver extremely fast and precisely controlled molten metal injection. This system works hand-in-hand with real-time closed-loop control systems that meticulously manage injection velocity and pressure, guaranteeing consistent quality with every single shot.

The entire operation is overseen by intelligent control via sophisticated PLC and HMI systems, which continuously monitor every aspect of the casting cycle, enabling precise adjustments and in-depth data analysis for ongoing optimization. Finally, these presses are engineered for integrated automation, seamlessly becoming part of fully automated casting cells that flawlessly integrate with ABB robotic ladlers, extractors, Wollin (Germany) sprayers, and deburring systems, ensuring maximum efficiency and safety in production. The fully enclosed quantitative furnace is from Striko Westofen in Germany, ensure more precise feeding.

Our Commitment to Innovation

Our commitment to providing cutting-edge manufacturing solutions is reinforced by the recent adoption of a BUHLER 4400-ton die casting press at one of our key Chinese suppliers. This investment not only expands our capacity but also elevates our ability to meet the most demanding requirements for complex, lightweight, and high-performance metal components.

We are incredibly excited about the opportunities this new capability brings and look forward to collaborating with you on your next-generation projects. How can our advanced BUHLER die casting and professional MAGMA (Germany) design capabilities help bring your designs to life?