Engineering Services: Capability & Production Control for Precision Manufacturing

In complex manufacturing projects, quality and cost are often discussed — but engineering control is what determines whether a project can move from concept to stable mass production.

At XY-GLOBAL, our engineering services are designed to bridge the gap between design intent and production reality.
We support customers through early-stage analysis, manufacturability evaluation, process planning, and production control — ensuring engineering decisions are not only correct, but executable.

1. Mold Flow Analysis: Engineering Validation Before Tooling

Before tooling begins, we conduct mold flow analysis to evaluate the feasibility and stability of the die casting process.

Using professional simulation tools (such as C3P / AnyCasting), our engineers analyze:

• Filling behavior and flow balance

• Potential cold shut, air entrapment, and oxide risk

• Filling time, gate speed, and punch speed

• Pressure and velocity distribution during filling

Typical analysis parameters include part weight, projected area, gate size, machine tonnage, and filling time.
The result is not a theoretical report, but a clear process window that guides gate design, runner layout, and machine selection.

This step allows potential casting risks to be identified and addressed before tooling investment, significantly reducing later rework or mold modification.

2. DFM Report: Design for Manufacturability Evaluation

Once the basic forming feasibility is confirmed, we perform a DFM (Design for Manufacturability) Report to evaluate whether the product design is suitable for stable production.

Our DFM analysis covers the full manufacturing chain:

Mold & Die Casting Structure

• Parting line (PL) suggestion

• Slider and core structure

• Gate location and ejection (EJ) arrangement

Product Structure

• Draft angle evaluation

• Wall thickness consistency

• Fillet (R) and structural reinforcement suggestions

CNC Machining & Finishing

• Machining strategy feasibility

• Tolerance requirements and optimization suggestions

• Surface finish requirements

Assembly & Packing

• Assembly clearance and structural conflict

• Packing and handling considerations

Rather than forcing design changes, our DFM report provides engineering suggestions with clear rationale, allowing customers to make informed decisions balancing function, cost, and manufacturability.

3. Mold Structure & Machining Strategy Engineering

Engineering decisions must be translated into concrete tooling and machining strategies.
Based on mold flow and DFM conclusions, our engineers further define:

Mold Structure Optimization

• Core, cavity, and slider configuration

• Gate layout and auxiliary flow channel design

• Ejector pin distribution with defined depth control (typically 0.1–0.2 mm sunken or machined flush for appearance control)

In some cases, temporary flow channels are introduced to improve filling speed and are later removed by CNC machining after casting — a typical example of engineering-manufacturing coordination.

Machining Strategy Before & After Anodizing

For parts requiring anodizing or other surface treatments, machining sequence becomes critical.

We clearly define:

• Which features must be machined before anodizing to ensure dimensional accuracy

• Which features must be machined after anodizing to protect appearance and function

• Fixture strategy to minimize re-clamping and cumulative tolerance error

Threaded holes, precision surfaces, and functional interfaces are evaluated individually to ensure both quality and production efficiency.

4. Tooling Production Schedule: Engineering Execution & Production Control

Engineering value is only realized when plans are executed accurately.
To ensure this, we provide customers with a Tooling Production Schedule that tracks both plan and actual progress.

The schedule covers:

• 3D drawing and mold drawing confirmation

• Material and die steel purchasing

• CNC rough and finish machining

• EDM, wire cutting, and heat treatment

• Core and cavity matching

Each stage is monitored with planned vs. actual status, supported by real production photos.
This approach transforms delivery from a promise into a controlled engineering process, providing transparency and predictable lead times.

Engineering Services That Support High-Requirement Industries

Our engineering services are widely applied in projects involving:

• Die casting components for industrial and automotive applications

• Precision CNC machined housings and structural parts

• Products requiring anodizing or high appearance standards

• Medium-to-large structural parts with tight tolerance requirements

By integrating analysis, DFM, machining strategy, and production control, we help customers reduce engineering risk, shorten ramp-up time, and achieve stable production faster.

From Engineering Decision to Production Reality

At XY-GLOBAL, engineering services are not isolated reports.
They are part of a closed-loop system connecting analysis, tooling, machining, and production execution.

Our goal is simple:
make engineering decisions that work — not only on paper, but on the production floor.