Die Spraying Tools | Contour Spraying Systems

Die Spraying in Die Casting

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Die Spraying Tools

Die Spraying Tools (Contour Spraying)

Die spraying tool for precise and uniform application of release agents and lubricants on die casting mold

Contour spraying for die casting molds uses robotic equipment to precisely and uniformly apply release agents and other media to designated areas of the mold surface, based on the three-dimensional shape, structural features, and preset paths of the mold cavity. Through “contour spraying,” the release agent only covers critical working surfaces such as mold cavities and runners, avoiding unnecessary spraying that causes waste or affects casting quality. It ensures uniform coating thickness to meet demolding requirements while preventing defects caused by excessive coating (such as bubbles and shrinkage porosity) or mold sticking caused by insufficient coating.

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Features

Working Principle

The clutch housing contour spraying fixture adopts a modular structure, designed according to cavity characteristics. It builds the spraying fixture and is equipped with an additional air-blowing function, enabling independent control of multiple spraying circuits and rapid drying of the mold cavity.

Contour Design and Easy Installation

Multiple modular contour assembly methods ensure smooth delivery of liquid and air channels, allowing the spraying fixture to be adapted precisely to the mold.

Multi-Angle and Adjustable Distance

With modular contour assemblies, spraying angles and distances can be flexibly adjusted.

Low Maintenance Cost

The modular contour structure helps reduce maintenance costs during later use. Only damaged connectors need to be replaced for continued use.

High Level of Design Professionalism

Professional 3D design of contour spraying fixtures enables spraying cycles of 25–30 seconds. With adjustments to the mold’s internal cooling structure, spraying cycles of under 20 seconds can be achieved.

Contour Nozzle

Micro spraying: Pure release agent with 100% active ingredients, water-based or oil-based, is precisely sprayed onto the mold surface using micro spraying equipment to form a lubricating isolation film.
Low-volume spraying: High-concentration pure release agent (generally not less than 1:10) is precisely sprayed onto the mold surface using micro spraying equipment to form a lubricating isolation film.
Mixed spraying: In one cycle, there can be a combination of two or three spraying methods among normal spraying, micro spraying, and low-volume spraying. Common combinations are normal/micro or normal/low-volume.

Main Components

Spraying fixture plate on the moving and fixed mold sides, length processed; surface with black anodizing.
Standard spraying mini valve.
Internal mixing nozzle IM3.0.
Additional air-blowing nozzle.
Nozzle mounting accessories.

Technical Specifications

Applicable release agents/die lubricants	Water-based, oil-based
Air pressure	4-6bar
Release agent transfer pressure	6-12bar
Spray method	Common spray
Spray circuits	4+4
Die spraying tool weight	Depending on actual application
Die spraying tool length	Depending on actual application

Mixing System

Working principle: The mobile EOC-type mixing station is mainly used for the mixing and pressurized delivery of die casting release agents. With an independent PLC control system and electronic flow meter for real-time flow monitoring, it achieves precise mixing of release agents for conventional spraying within a ratio range of 1:50 to 1:300. It can also monitor and measure the spraying consumption for each mold.
Level display and alarm: Provides liquid level display (including mixed liquid and release agent stock solution) and level alarm functions.
Multiple pressure adjustments: The mixed liquid is pressurized and delivered through a variable frequency pump. Within the 0–12 bar pressure range, adjustment can be made via the operation interface to ensure constant pressure and stable output.
High accuracy: The quantitative accuracy of the mixed liquid ratio is controlled within ±3%, ensuring stable concentration of the mixed liquid.
Flow recording: Monitors the consumption of release agent mixed liquid per mold, with usage alarm function. Automatically generates and stores historical flow records for up to 30 molds.
Manual control: The mixing tank is equipped with a ball valve outlet switch interface, allowing manual control of all actuators and valves for quick cleaning of the mixing tank.

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Why choose this equipment? What value does it create?

Integrated design: CTM water temperature units centralize low (5–35℃), medium (50–120℃), and high (120–160℃) temperature zones, reducing equipment footprint.
Wide temperature range: Capable of controlling between 20℃ and 320℃ to cover multiple die casting stages.
Energy efficiency: Integration reduces the number of units required, lowering overall energy consumption. For example, total energy demand for a large-scale island can be reduced from 1680KW to 360KW.

What value does it create for customers?

Lower procurement cost by reducing the number of units required (savings of more than 30% possible).
Space savings due to compact design.
Reduced maintenance cost thanks to fewer devices and easier management.
Improved product quality and efficiency: precise temperature control ensures higher accuracy and better casting results. Automated control (ThermLoop) can reduce die casting cycle time by 15–30% while maintaining quality.

What is the warranty period and what does it include?

Standard warranty is 12 months from acceptance. It covers non-human faults with free repairs, replacement of faulty parts, and technical support.

Which parts need replacement and how often?

Temperature sensors: every 1–2 years.
Heating tubes: every 1–3 years depending on usage.
Seals: check every 6–12 months, replace if necessary.
Filters: replace every 1–3 months depending on contamination.

What if after-sales response is delayed?

A response system is in place with performance tracking. If service is unsatisfactory, customers may escalate complaints to customer support, which ensures follow-up by assigned personnel.