PRODUCTS

DongGuan TongToo Aluminum Products Co., Ltd. is a company specializing in aluminum alloy CNC precision machining, injection molding, mold development, and metal parts manufacturing. It has obtained ISO 9001 international certification and strictly implements the 6S management system. With the introduction of German imported equipment, its products are exported to more than 20 countries including Europe, America, and Southeast Asia, with an average annual delivery volume of more than 5 million pieces. With exquisite craftsmanship, fast response, and full-process quality inspection as the core, we provide customized ODM/OEM solutions for global customers and strive to become a trusted strategic partner in the field of international industrial manufacturing.

Product Introduction

This product is made of high pressure die casting (HPDC) and uses ADC12/A380 aluminum alloy as the base material to achieve integrated molding of complex structures. It is designed for electrical connection protection in harsh environments, integrating ultra-thin wall thickness design (thinnest 1.5mm), IP68-level sealing performance and EMC electromagnetic shielding characteristics. It supports full-process aluminum casting customization services from mold development to mass production, meets the explosion-proof, corrosion-resistant and high heat dissipation requirements in new energy, industrial automation and other fields, and provides flexible supply chain solutions from small batch quick response to 10,000-ton die-casting mass production.

Product Parameter

Product Name Aluminum Alloy Junction Box Shell

Product Material ADC12/A380

Processing Technology: Precision Die Casting + CNC Milling

Surface Treatment: Sandblasting + Electrophoresis + Spraying

Product Features: Modular structure, supports personalized opening, size, LOGO customization

Product Feature And Application

Advantages of Die Casting Process

Complex structure one-piece molding: seamless manufacturing of multi-curved/special-shaped cavities through precision die-casting molds, eliminating splicing gaps

High-precision dimensional control: tolerance can reach CT6 level (±0.25mm), reducing secondary processing costs

Ultra-thin wall thickness design: wall thickness 1.5-3mm (conventional sheet metal process minimum 2.5mm), weight reduction 30%+

Deep customization capability

Flexible mold development: support single-hole/multi-hole molds, rapid response to design changes (T1 sample 7-15 days)

Functional integration innovation: embedded copper nut inserts (tensile strength > 6kN)

Integrated die-casting of heat sink fins

Inner cavity insulation coating (withstands 5kV)

Closed-loop recycled aluminum: using 30%+ recycled aluminum raw materials (in compliance with ISO14064)

10,000-ton die-casting island: 3500T-8000T large-scale die-casting machine mass production, daily production capacity of 10,000+ pieces

Intelligent deburring: robot polishing + CNC fine milling, Ra＜1.6μm

Application scenarios:

New energy power system

Photovoltaic field: string photovoltaic junction box, inverter lightning protection terminal box

Energy storage equipment: battery cluster high-voltage connection warehouse

Charging pile: DC fast charging gun body die-casting shell (liquid cooling channel integrated design)

Industrial automation

Explosion-proof control system: chemical zone intrinsically safe Ex ia junction box (die-cast flameproof cavity)

Robot cable management: articulated arm waterproof adapter box (anti-vibration design)

Distributed I/O station: PROFINET bus protective shell

Special field

Ship electrical: waterproof wiring compartment

Railway transportation: aluminum casting protective box for signal equipment

Medical equipment: high shielding junction box for surgical instruments

Product Details

Indicators Standard die-casting Custom enhanced

Base material ADC12 (AISi10Cu3) A380 (high fluidity)

Tensile strength ≥240MPa ≥320MPa (vacuum die-casting)

Protection level IP65 (standard) IP68/IP69K

Corrosion resistance 500h salt spray test 1000h salt spray (anodizing + coating)

Flame retardant level (CASS) UL94 HB UL94 V-0 (magnesium aluminum alloy)

Working temperature -40°C~+120℃C -60℃℃~+150°C

Minimum batch 100 pieces (small batch trial production) 5,000 pieces (mass production optimization)

Product Qualification

Environmental certification:

RoHS certification (lead-free, cadmium-free and other hazardous substances)

REACH (EU Chemical Safety Standard)

Quality management system:

ISO 9001:2016/ISO 9001:2015 (production process quality control)

Deliver, Shipping And Serving

Professional ODM & OEM manufacturer, with more than 20 years of precision machining experience, based on customer needs, providing a full range of customized services.

Standard packaging: copy paper + carton

Customized packaging: blister tray / pearl cotton + wooden box

Packing solution: pearl cotton + carton/wooden box.

FAQ

Q1: Die-cast aluminum alloy junction box vs sheet metal / extrusion process difference?

A: Complex structure molding: can integrate heat sink / embedded parts / special-shaped cavity

Low mass production cost: large batches of unit prices compared to CNC processing by 50% +

Excellent surface quality: high density of die-casting surface, strong coating adhesion

High initial investment: need to develop die-casting molds (cost ranging from 10,000 to 280,000)

Design limitations: not suitable for ultra-thin flat parts (risk of deformation)

Q2: How to solve defects such as pores and sand holes in die-casting parts?

A: Five quality control methods are adopted:

1. Vacuum die-casting technology: cavity vacuum degree ≤80mbar, reduce bubbles

2. Mold flow analysis and optimization: MAGMA software simulates the filling process

3. X-ray non-destructive testing: 100% industrial CT scanning of key areas

4. T6 heat treatment: enhance density (hardness up to HB90+)

5. Porosity control: <0.1%

Q3: How long does it take to customize an aluminum alloy shell?

A: The customization cycle depends on the complexity of the design, whether mold opening is required (such as extrusion mold/die-casting mold), production quantity and surface treatment process. Usually:

CNC prototype proofing: 3-7 working days (provide 3D drawings).

Small batch customization (no mold): 7-15 working days (based on sheet metal processing and CNC).

Involving extrusion mold development: mold making time (usually 2-4 weeks) + production time.

Middle and large batch production: high efficiency after the mold/process is finalized. We provide quick response service and can communicate specific urgent needs.

Q4: What is the minimum order quantity (MOQ) for customization?

A: We understand the needs of customers at different stages (R&D, trial production, mass production). For non-standard customization:

CNC processing/sheet metal bending: usually support small batch orders, or even single-piece proofing.

Profile boxes that require extrusion dies: There will be a minimum order quantity requirement for the first production (to share the mold cost), and the specific quantity depends on the complexity and size of the profile section, which can be negotiated. There is no minimum quantity limit for subsequent orders (but the unit price is better for larger quantities).

Q5: What do I need to provide to start customization?

A: The more detailed information you provide, the more accurate and efficient the customization. Ideally, please provide:

3D model files (STEP, IGS, X_T and other formats are best).

Clear 2D engineering drawings (marking key dimensions, tolerances, opening requirements, surface treatment, etc.).

Written technical requirements: including but not limited to material requirements, protection level (IPXX), heat dissipation requirements, EMC requirements, internal installation requirements (guide rail/copper column position), lock/hinge type, surface treatment color and process, certification requirements, etc.

If there is only a concept or sketch, our engineering team can provide design support and jointly optimize the solution.

Q6: Can small batch customization (within 100 pieces) be achieved? How to control costs?

A: Flexible production plan:

Within 50 pieces: CNC machining + sheet metal process (free mold opening fee)

100-500 pieces: combined mold solution (reduce mold cost by 30%)

>500 pieces: extrusion mold/die-casting mold optimizes mass production cost

Reduce customization costs through standardized module libraries (such as sealing structure/mounting hole position)

Company Introduction

Our 5000㎡ workshop is equipped with hundreds of production equipment, including German Hammer five-axis CNC machining center (machining accuracy up to 0.002 MM), turning and milling composite CNC lathe, CNC lathe, milling machine, lathe, grinder, etc.; as well as more than a dozen various inspection equipment (including German Cai's three-dimensional, with inspection accuracy up to 0.001MM), and the machining capacity has reached the international advanced level. The Tengtu team has the most professional mold design and CNC machining knowledge. We will work closely with you during the prototyping, production, assembly, inspection, packaging and final delivery process to exceed your expectations.

Our team uses CNC machining to manufacture high-performance parts that support industries such as aerospace, automotive, military, medical, machinery, electronics, and communications. We are committed to innovation and manufacture and assemble important components with excellent precision, strict tolerances and high-quality materials. Over the past 11 years, Tengtu has established a high reputation for efficiency, quality, reliability and on-time delivery.