A380 fills a die that carries the fin field on the outside and the panel openings on the front. The openings are formed by die blocks rather than cored holes, so their edges come out clean and square. After casting the mating face is fly-cut, the screw holes are drilled and tapped, and the part is coated black with the mating face masked so it still seals against its gasket. The connector-panel boxes in the die casting heat sink range are coated the same way, with the mating face left bare. How gas entrapment is kept away from that mating face is covered in porosity in die castings.
One die makes both.
Cast in, not milled after.
Connectors sit below the rim.
Tapped after casting.
Nothing cut after the box is closed.
| Base Material | A380 aluminum, high-pressure die casting, black coating |
|---|---|
| Enclosure | Sealed box with cast fins on top |
| Front Panel | 4 connector cutouts, cast in the die |
| Mounting | Cast screw bosses, tapped |
| Side | Recessed grip groove |
| Finish | Black coating, mating face masked |
| Base CNC Tolerance | Milling / drilling / tapping down to +/-0.005 mm |
| Dimensional Inspection | Hexagon CMM +/-0.001 mm; 2.5D optical projector |
| Quality System | ISO 9001:2015; IATF 16949:2016 |
| Capacity | 60,000+ thermal parts per year |
| Lead Time | Samples typically 7-15 days; production scheduled to volume |
Note: values above are KingKa build options and verified capability; final geometry, holes and finish are confirmed against your drawing.
A panel opening that sits on the parting line leaves a witness mark across the connector face. Moving it a few millimetres off the line costs nothing in the design and saves the cosmetic rework that otherwise lands on every unit.
Design & CFD. 3D layout with CFD review sizes the fin field, pipe route and base thickness to the load and airflow.
Base machining. Plate, pockets and pipe channels are milled on 50+ CNC centers to +/-0.005 mm.
Fin and pipe joining. Fins skived, stacked or extruded; pipes pressed and soldered; the stack joined to the base by the process the design calls for.
Face fly-cutting. Contact face machined flat after joining so the part sits true on the device.
Final inspection. Hexagon CMM (+/-0.001 mm) and 2.5D projector check critical features; 4-stage IQC / IPQC / FQC.
Fin pitch and height - measured against the drawing before packing.
Base flatness - fly-cut face checked on the contact side.
CMM report - critical dimensions to +/-0.001 mm.
Joint inspection - solder or weld fillet checked along the stack feet.
Visual and batch audit - IQC / IPQC / FQC on every run.
Instrument boxes with cast panels are used where the connector layout is fixed:
Bench instruments
RF and amplifier units
Broadcast equipment
Test and measurement
Industrial controllers
Send the front panel drawing with the connector cutouts, the board height inside, the gasket requirement and the coating colour. KingKa checks the cutouts against the die's parting line first - an opening that crosses the parting line needs a slide, which changes the tool. For an outdoor unit with lifting handles and a pole mount, the outdoor die cast box comes from the same casting family.
KingKa is a direct manufacturer with 16+ years in thermal production, 50+ CNC centers, in-house skiving, FSW and vacuum brazing, certified to ISO 9001:2015 and IATF 16949:2016.
Send the panel drawing and the die line will decide the rest. Cutouts near the edge or across the parting line move the tool price more than the size of the box does.
One supplier for the whole assembly. Base, fins, pipes and hardware under one quality system.
CFD before tooling. Design review catches a bad layout before metal is cut.
Prototype to volume. Samples in 7-15 days, production scheduled to forecast.
