Graphic 3D design - Zhejiang Ningbo Hexin focus on low pressure casting, gravity casting, die casting mold manufacturing, aluminum casting factory

3D Product Design

Ningbo Hexin Molding Co., Ltd. specializes in providing innovative solutions to customers through high-precision mapping and reverse design technology. Relying on advanced mapping equipment and professional software, the company accurately collects spatial data of objects and builds digital models to realize efficient reverse design in the fields of machinery manufacturing, industrial design, and building renovation. The team restores the details of product structure through refined mapping, optimizes the prototype with forward design thinking, helps customers to complete product iteration, process upgrading and technological transformation, and successfully delivers a number of complex projects in the scenarios of equipment manufacturing, cultural relics preservation, mold development, etc., which helps enterprises to reduce costs and increase efficiency with data-driven design.

Product Reverse Design

Ningbo Hexin Molding Co., Ltd.’s reverse engineering process is based on high-precision 3D laser scanning and UAV surveying technology. Through five core steps—[data acquisition, 3D scanning and modeling, feature analysis, CAD model reconstruction, and prototype optimization]—it accurately recreates digital models of complex components, industrial equipment, and architectural structures. By integrating forward-design thinking to optimize product performance and manufacturing processes, the company provides production-ready technical solutions for mechanical manufacturing, mold development, product comparison, and other fields. Through data-driven reverse engineering, it helps enterprises shorten R&D cycles, reduce modification costs, and enhance market competitiveness.

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3D Mold Design

3D mold design uses digital technology to accurately build mold structure, covering die casting, low pressure and gravity casting three major processes, helping enterprises to efficiently produce high-precision parts. Die casting mold design is good at manufacturing complex parts (such as auto parts, electronic shell), relying on high-pressure high-speed filling technology, to ensure that thin-walled parts of the surface finish and dimensional precision, the core focus on the mold pressure strength and cooling efficiency; low-pressure mold design to fill the cavity with smooth low-pressure (0.01-0.05MPa) to reduce the defects of the air holes, adaptable to the aluminum alloy wheels and other high requirements of the densification of the large and medium-sized products, focusing on Optimization of pouring system and shrinkage channel; gravity mold design by virtue of the natural molding of metal weight, low cost, short cycle time, suitable for pipeline joints and other simple structure of the mass production, need to be targeted to solve the problem of insufficient filling and shrinkage. All three types of processes can be used to pre-judge defects through 3D modeling and simulation analysis (e.g., melt flow simulation, thermal stress detection), optimize parting surfaces and exhaust design, and reduce molding costs while improving yields, so as to meet the diversified demands for precision castings in automotive, aerospace, and home appliance industries.

Die Casting Mold Design

Hersin uses advanced CAD/CAM software (e.g. SolidWorks, AutoCAD) to achieve high-precision digital development of molds and optimize runner systems, cooling structures and ejection solutions to improve mold life and productivity. Our design services cover automotive parts, electronic parts, household appliances and other die casting areas, through 3D simulation verification to reduce the cost of trial mold, to ensure the accuracy of the parting surface and tolerance ± 0.01mm control, to support the design of complex curved surfaces and thin-walled structures, to help companies to shorten the development cycle of 30% products. Provide customized mold frame, slide and exhaust system solutions, in line with ISO9001 standards, to meet the needs of zinc/aluminum/magnesium alloy die casting process, click on the consultation to get a free design plan!

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Gravity casting mold design

Based on ProCAST, AnyCasting and other simulation software to realize the digital development of metal-type molds, accurate design of the pouring system, mold temperature control and exhaust structure, to meet the needs of complex thin-walled parts and thick-walled castings process. We focus on automotive engine block, hydraulic valve body, aerospace parts and other gravity casting field, through 3D simulation to optimize the filling speed and solidification sequence, reduce shrinkage and porosity defects, and improve the yield rate by more than 20%. Adopting parametric modeling technology to ensure the accuracy of mold parting surface ±0.02mm, supporting the design of sand core embedding and block combination to meet the casting characteristics of aluminum/copper alloy. Provide a full range of services from mold structure optimization to process verification, in line with ISO certification standards, to help companies reduce the scrap rate of 15% and shorten the production cycle of 25%, click to get the industry customized solutions!

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Low pressure casting mold design

Relying on UG, Pro/E and other professional CAD tools, as well as MAGMASOFT and Flow-3D simulation technology, we can realize accurate development of mold structure, optimize pouring system, pressure control and mold temperature field distribution, and meet the needs of production of complex thin-walled parts and high-strength castings. We are deeply engaged in the field of low-pressure casting of automotive aluminum alloy wheel hubs, new energy motor shells, aerospace precision parts, etc. Through 3D dynamic simulation to verify the smoothness of the liquid metal filling, effectively reduce the air-rolling, shrinkage and loosening defects, and improve the yield rate. 15%-20% adopts the modular design concept to support the multi-cavity module and quick mold change structure, with a tolerance control of ±0.03mm, which meets the requirement of low-pressure slow-speed filling of aluminum/magnesium alloys and the need for production of complex thin-walled parts and high-strength castings. Magnesium alloy low pressure and slow filling process characteristics. Provide mold life prediction, cooling system optimization and gate program customization services, in line with IATF16949 standards, to help companies reduce 25% mold cost and shorten the development cycle of 30%, click on the consultation to get a free process simulation report!

3D Design and Digital Engineering Services

Ningbo Hexin Molding Co., Ltd. offers a range ofProduct Reverse Engineering, Conversion of 2D Engineering Drawings to 3D Models, 3D Design of Casting MoldsDigital engineering services in three major areas. Leveraging mainstream CAD platforms such as SolidWorks, UG/NX, and AutoCAD, combined with mold and flow simulation tools like ProCAST, MAGMASOFT, and Flow-3D, Hexin uses digital modeling and simulation analysis early in the mold development process to predict casting defects and optimize gating systems, thereby limiting the number of trial runs and mold modifications toWithin 2 rounds... effectively shortening the mold development cycle and reducing trial-and-error costs.

Service Focus:3D design is the front-end engineering phase of casting mold development. Hexin provides integrated services ranging from product surveying and mapping → 3D modeling → mold design → mold flow simulation → mold manufacturing. Data flows seamlessly across all stages, preventing rework and information loss caused by a disconnect between design files and the manufacturing process.

Product Reverse Engineering Process

For physical parts without original drawings, replacement parts for aging molds, or competitive product analysis, He Xin usesHigh-Precision 3D Scanning + CAD Model ReconstructionUsing reverse engineering methods, physical parts are converted into editable, optimizable digital models. The five stages of the end-to-end process are closely interlinked, ensuring that the accuracy of the reverse-engineered models meets engineering and manufacturing requirements:

3D Data Acquisition

Point cloud data of the part's surface is captured using a laser scanner or structured light system, with a scanning accuracy of ±0.02 mm, enabling the capture of complex surface curvatures, fillet transitions, and minute feature details.

Point Cloud Processing and Modeling

Perform noise reduction, stitching, and surface fitting on point clouds in Geomagic Design X / SolidWorks to generate a triangular mesh model (STL format) and fill in scanning blind spots.

Feature Extraction and Analysis

Identify key geometric features—reference planes, locating holes, mating surfaces, and wall thickness distribution—and extract dimensional and geometric tolerance information to provide a basis for parametric modeling.

CAD Model Reconstruction

Based on the results of the feature analysis, reconstruct a parametric solid model in CAD software, correct scanning defects, and add draft angles (1°–3°) and casting fillets (R ≥ 1.5 mm).

Forward Optimization Validation

Optimize the model’s structure using forward design thinking, verify manufacturability through CAE simulation, and produce engineering drawings (including dimensional and geometric tolerances) and production models.

Converting 2D Engineering Drawings to 3D Models

Based on the information provided by the customer2D Engineering Drawings (DWG/DXF/PDF)Based on this, parametric CAD modeling tools are used to convert plan views, dimensional annotations, section symbols, and tolerance information into precise 3D digital models. This process requires designers to possessAbility to Interpret Engineering Drawingsrespond in singingAbility to Reconstruct Spatial Geometry, to ensure that the model is consistent with the design intent of the drawings:

Drawing Analysis

Analyze the dimensional annotations, tolerance requirements, and surface roughness symbols in each of the three views (front view, top view, and side view) and the sectional view, and identify key reference planes and fit relationships.

Basic Modeling

In SolidWorks, UG, and NX, basic geometries are created using operations such as extrusion, rotation, sweeping, and lofting, with model parameters strictly driven by the dimensions specified in the drawings.

Add Detailed Features

Add detail features such as chamfers, fillets, draft angles, threaded holes, and ribs, and adjust the dimensional accuracy to ±0.02 mm according to the drawing annotations.

Assembly Verification

Perform interference checks and motion simulations on multi-part assemblies to verify clearance and range of motion, ensuring that the 3D models meet assembly and operational requirements.

3D Design of Casting Molds

He Xin CoverageHigh-pressure die-casting molds, low-pressure die-casting molds, gravity die-casting molds3D Design of Molds for Three Types of Casting Processes. Different casting processes have significant differences in terms of mold strength requirements, cooling design, parting line strategies, and venting layouts. The following sections cover these topics one by one, from design parameters to simulation methods:

Die Casting Mold Design

Parting Line Accuracy±0.01 mm

Mold MaterialsH13 / SKD61 Hot-Work Steel

Cooling DesignCustom-Shaped Water Channels + Spot-Cooling Pipes

Simulation ToolsFlow-3D / MAGMASOFT

Slider MechanismHydraulic Core Pull / Angled Guide Pins

typical applicationAutomotive Parts, Electronic Enclosures

High-pressure, high-speed filling (filling speed of 50–100 m/s) requires the mold to have high pressure resistance and efficient cooling capacity. Design priorities: ① Optimization of the gate and runner system—determine the location, cross-sectional area, and layout of the overflow channels via mold flow simulation to ensure balanced filling; ② Cooling channel design—Employ conformal cooling channels to control the mold temperature field (180–220°C) and prevent mold sticking caused by hot spots; ③ Venting system—Install vent grooves (depth 0.08–0.15 mm) at the parting line and core areas to reduce air entrapment defects.

Low pressure casting mold design

Parting Line Accuracy±0.03 mm

Mold MaterialsH13 / QT500-7 Ductile Iron

Casting MethodBottom Injection via Riser + Pressure Maintenance and Shrinkage Compensation

Simulation ToolsProCAST / MAGMASOFT

Filling Pressure0.02–0.08 MPa

typical applicationAluminum alloy wheels, motor housings

The process characteristics of laminar filling (filling velocity 0.05–0.5 m/s) combined with pressure feeding (0.1–0.3 MPa) dictate that the core of mold design lies in the gating system and feeding channels. Design Focus: ① Riser diameter and gate location—to ensure smooth rise of molten aluminum and a uniform temperature distribution; ② Sequential solidification control—to ensure unobstructed flow in the feed channels through mold temperature distribution design and localized cooling/heating; ③ Venting design—install vent plugs (φ6–φ10 mm) at the highest point and the far end of the cavity to prevent gas entrapment.

Gravity casting mold design

Parting Line Accuracy±0.02 mm

Mold MaterialsQT500-7 / HT250

Casting MethodGravity Top-Pouring/Bottom-Pouring + Risers for Shrinkage Compensation

Simulation ToolsAnyCasting / ProCAST

Sand Core FitMetal Mold + Resin Sand Core

typical applicationEngine manifolds, pump housings

Gravity casting relies on the geometric design of the gating system to control flow patterns; while mold costs are low, specific solutions are required to address insufficient filling and shrinkage porosity. Design priorities: ① Gating system—design of the cross-sectional area of the horizontal runner and the height of the vertical runner to ensure a moderate filling rate (to avoid turbulence); ② Sprue layout—calculate sprue positions and dimensions using the hot-spot method to achieve sequential solidification; ③ Sand core integration—combined design of metal molds and resin sand cores to accommodate complex internal cavity structures.

A Comprehensive Comparison of Three Types of Casting Mold Design Parameters

Design Parameters	Die-Casting Molds (HPDC)	Low-Pressure Casting (LPC) Molds	Gravity Die Casting (GDC)
Parting Line Accuracy	±0.01 mm	±0.03 mm	±0.02 mm
Mold Materials	H13 / SKD61 Hot-Work Steel	H13 / QT500-7	QT500-7 / HT250
Mold life	80,000–150,000 cycles	30,000–50,000 cycles	20,000–100,000 cycles
Cooling Method	Custom-Shaped Water Channels + Spot-Cooling Pipes	Water-Cooled/Air-Cooled, Zone-by-Zone Temperature Control	Natural cooling / Local forced air cooling
Exhaust Design	Parting Line Vent Grooves (0.08–0.15 mm)	Vent Plug (φ6–φ10 mm)	Parting Line + Sand Core Venting
Slider/Core Pull	Hydraulic Core Pull / Angled Guide Pins	Hydraulic Core Pull / Manual	Manual / Angled Guide Pins
Slope of Drawing	1°–2° (internal) / 0.5°–1° (external)	1.5°–3°	2°–5°
Mold Development Cycle	25–40 days	20–30 days	15–25 days
Number of Trial Mold Adjustments	≤2 rounds	≤2 rounds	≤2 rounds
Mold Costs (Relative)	your (honorific)	center	Low to Medium
Adapted to Casting Wall Thickness	1–6 mm	3–15 mm	4–30 mm
Typical Products	Automotive Sensor Housings, Electronic Heat Sinks	Aluminum Alloy Wheels, New Energy Motor Housings	Engine manifolds, hydraulic valve bodies

CAE Mold Flow Simulation and Defect Prediction

He Xin incorporated this into the mold design phaseCAE Casting Simulation Analysis...uses numerical simulation to predict the filling behavior of molten metal in the mold cavity, the solidification process, and potential casting defects, thereby optimizing the design before the mold is machined. Core simulation capabilities cover the following areas:

Charging process simulation

Simulate the flow path, filling rate, and temperature distribution of molten metal within the mold cavity; predict defects such as entrapped gas, cold shuts, and underfill; and optimize the location of the internal gate and the cross-sectional area of the runner.

Analysis of the Solidification Process

Calculate the solidification sequence and solidification times for various sections of the casting; identify isolated liquid zones and hot spots; predict the likelihood of shrinkage porosity and shrinkage cavities; and optimize the layout of the risers and the cooling system.

Thermal Stress and Deformation

Analyze the distribution of thermal stresses and deformation trends in castings during solidification and cooling to predict the risk of hot cracking and dimensional deviations, and guide the design of mold counter-deformation compensation.

Mold Temperature Distribution

Simulate the temperature distribution and thermal equilibrium of the mold during continuous production to optimize the layout of the cooling channels and the parameters of the cooling medium, ensuring that the mold temperature remains stable within the process window (±10°C).

Common Technical Issues in 3D Design and Mold Development

Q: What level of accuracy can reverse engineering scans achieve? Can they meet the requirements for mold manufacturing?

The high-precision laser scanner used by He Xin achieves a scanning accuracy of ±0.02 mm in standard mode, which meets the design requirements for the vast majority of casting molds. However, it is important to note that scanning accuracy does not equate to the accuracy of the final model—the key to reverse engineering lies in the CAD model reconstruction phase following point cloud processing. Designers must identify scanning noise and true geometric features, and correct them through parametric modeling. For critical features such as mating surfaces and locating holes, He Xin performs physical verification using a coordinate measuring machine (CMM) after reconstruction to ensure the model’s accuracy meets engineering requirements. If a part contains scanning blind spots—such as deep, narrow grooves or small-diameter deep holes—manual measurements may be required to supplement the data.

Q: If I only have 2D drawings and no 3D models, can I proceed directly with mold design?

Yes. He Xin offers comprehensive services for converting 2D engineering drawings into 3D models and supports input of drawings in formats such as DWG, DXF, and PDF. However, it should be noted that the completeness and accuracy of the 2D drawings directly affect the quality of the 3D modeling—if the drawings contain dimensional inconsistencies, missing views, or unclear tolerance annotations, the designers will need to confirm these details with the client before proceeding with modeling. For complex curved parts (such as impellers and volutes), 2D drawings often cannot fully represent 3D surface information. We recommend providing physical samples for reverse engineering and scanning, as this approach is more efficient and ensures greater accuracy.

Q: Can mold flow simulation replace mold testing? Or is mold testing still necessary for validation?

Mold flow simulation cannot completely replace mold trial runs, but it can significantly reduce the number of trial runs required. He Xin’s practical experience shows that thorough CAE simulation can reduce the number of mold trial runs and modifications from the traditional 4 to 6 cycles to fewer than 2 cycles. The reasons why simulation cannot replace trial molding are: (1) Simulation models themselves rely on simplifying assumptions (such as interfacial heat transfer coefficients and material constitutive models), which result in deviations from actual operating conditions; (2) Variables in the production process (such as fluctuations in molten aluminum temperature, uniformity of mold preheating, and the effectiveness of release agent spraying) are difficult to fully replicate in simulation. The correct approach is "simulation first, trial molding verification"—using simulation to screen for the optimal solution, then using trial molding to finally confirm and fine-tune the process parameters.

Q: What software does He Xin use for mold design? Can it directly interface with the client’s design file formats?

He Xin primarily uses SolidWorks and UG/NX for 3D mold design and supports direct import of mainstream CAD formats (STEP, IGES, X_T, STL, DWG, DXF, etc.). He Xin can also directly read and edit native CAD files provided by customers (such as SolidWorks .sldprt, CATIA .CATPart, and Pro/E .prt). If clients use other CAD platforms, we recommend exporting files in STEP AP242 format, which preserves geometry and assembly relationships, resulting in minimal data loss during conversion. For mold flow simulation, Hexin uses professional tools such as ProCAST, MAGMASOFT, and Flow-3D, and can generate detailed simulation analysis reports for client review.

Do you need reverse engineering or 3D mold modeling services?

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