Your Partner in Innovative Product Development!
CASTMAN is your ultimate partner for creating revolutionary products. From initial concept to final production, collaborate with our expert engineering team to bring your vision to life. We are dedicated to understanding your unique requirements and relentlessly pursuing solutions to build a better product, together.
CASTMAN Products & Solutions
Are you searching for a reliable partner for high-pressure die casting (HPDC) mold design and fabrication? If you are planning to develop or mass-produce aluminum die-casting products, do not hesitate to contact CASTMAN.
Phone: +82-31-351-5022
Email: sales@castman.co.kr
We also provide comprehensive design and drawing reviews for cost reduction.
Why Choose CASTMAN? Our Differentiated Services
We provide end-to-end services related to die-cast products, from material selection, DFM (Design for Manufacturing) analysis, simulation, and mold making to mass production and cost reduction strategies.
- Unmatched Quality & Technical Expertise
We supply die-cast components to leading domestic and international automotive companies, an industry where price and quality are paramount. This is your assurance that you can expect the highest level of service. - Comprehensive Turnkey Services
Our team of professional engineers, each with over 25 years of experience in fields like materials, casting, machining, mold design, and quality, manages the entire process from development to mass production. - Deep Material Expertise
Leveraging our specialized knowledge, we possess a deep understanding of each material's characteristics and apply this insight to optimize product design and production. - Extensive Experience & Professionalism
Our engineering team will propose optimal design solutions that perfectly reflect your ideas and requirements. - Optimized Design Through Simulation
Utilizing the latest numerical analysis technology, we apply the most efficient product designs and casting methods. - Rigorous Quality Control
Quality is our top priority. We adhere to strict quality control procedures at every stage of production. - Proven Experience Across Diverse Industries
We have extensive experience in product development and production across various sectors, including electric vehicles (EV), medical devices, furniture, lighting, home appliances, and telecommunications. - Competitive Pricing & Fast Turnaround
Through competitive pricing and efficient production processes, we guarantee rapid product development and on-time delivery.
With CASTMAN, you no longer need to worry about technical capabilities or cost-competitiveness!
We Solve All Your High-Pressure Die Casting Challenges!
Do you feel that it's becoming difficult to secure a technological edge or cost-competitiveness with conventional aluminum HPDC production methods?
CASTMAN resolves your concerns by providing every service related to die-cast product manufacturing—from mold design and fabrication to mass production—all in one place. Experience superior products and innovative solutions with our comprehensive development and mass production services.
CASTMAN is always committed to meeting your requirements and resolving your challenges.
Q1. What is CASTMAN's core competency, and what differentiates you from other die casting companies?
CASTMAN is more than just a parts manufacturer; we are a technology partner that brings our clients' innovations to life. Our core competency lies in our world-class 'Salt Core' technology and our proven capability for mass-producing high-difficulty 'Aluminum, and Copper Die Casting' parts. These two unique technologies enable us to achieve what is impossible with conventional methods: creating complex internal geometries, integrating multiple parts, reducing weight, and maximizing performance simultaneously. We offer a one-stop solution covering everything from initial Design for Manufacturing (DFM) reviews and simulations to mold fabrication, mass production, and post-processing. This provides true value by reducing product development risks and shortening time-to-market, which fundamentally differentiates CASTMAN from other suppliers.
Q2. What are the specific advantages of 'Salt Core' technology, and for which parts is it most effective?
Salt Core technology is an innovative process that uses a water-soluble salt core, which is completely washed out after casting, to create 3D internal channels or hollow structures within a single part. It eliminates the need for welding or assembling multiple components, which inherently prevents leakage risks and dramatically improves product reliability and durability. This technology is most effective when applied to high-performance, high-efficiency products such as motor housings, battery cases, and cooling plates for electric vehicles, as well as aerospace and defense components where internal weight reduction is critical.
Q3. Copper die casting is known to be technically very challenging. How has CASTMAN overcome this?
Copper has a much higher melting point than aluminum and shortens mold life, making it an extremely challenging material for die casting. To overcome this technological barrier, CASTMAN has built a proprietary technology portfolio through years of R&D. First, we developed mold technology that withstands copper's high temperatures and special surface coatings that extend mold life. Second, we possess specialized manufacturing techniques tailored to the unique properties of copper. Finally, we use CAE casting analysis to predict defects in advance and establish optimal casting conditions. This combination of technical expertise allows us to reliably mass-produce various industrial and automotive parts requiring high electrical and thermal conductivity.
Q4. With which global industry leaders does CASTMAN primarily collaborate?
We supply critical components to global leaders in various cutting-edge industries that demand high levels of technology and reliability. The most prominent sector is the electric vehicle (EV) industry, where our technology is widely recognized for drive motors, inverter housings, and battery system components. We are also a key partner in the 5G telecommunications sector for thermal management parts, the defense and aerospace industries where precision is vital, the medical device field, and the next-generation robotics industry. By focusing on these technology-intensive sectors, we go beyond simple parts supply to contribute to the technological advancement of each industry, working together with our clients to solve their most challenging problems.
Q5. We are in the early design stage. Can we receive technical support (DFM) to optimize our product design for die casting?
Absolutely. The key to successful mass production lies in optimization during the initial design phase. CASTMAN considers Design for Manufacturing (DFM) support to be a critical service and actively participates as our client's core technology partner. Our team of expert engineers will review your initial design and propose optimized modifications, such as wall thickness adjustments, ideal draft angles, solutions for undercut features, and optimal gating and overflow placement to minimize casting defects. Through this collaborative process, you can prevent potential manufacturing issues, achieve both quality improvements and cost reductions, and even shorten your overall development timeline.
Q6. How is CASTMAN's quality assurance system operated, and what certifications do you hold?
Based on the philosophy that 'quality is a non-negotiable value,' CASTMAN operates a world-class quality assurance system. We are certified in the automotive industry's stringent IATF 16949 quality management system, as well as ISO 9001 (Quality Management) and ISO 14001 (Environmental Management). From the development stage, we perform precise analysis using 3D scanners and CMMs. During mass production, we not only monitor process data in real-time but also thoroughly manage unseen internal defects with X-ray non-destructive testing. For parts requiring leak-proof performance, we conduct 100% leak testing. Through this systematic process, we promise to deliver only zero-defect products to our customers.
Q7. What is the range of sizes and weights for aluminum die-cast parts that you can produce?
To meet the diverse needs of our customers, we have a wide range of equipment capable of producing everything from small, precision components to large structural parts. We operate a variety of die casting machines, from small 150-ton to 900-ton machines. The exact producible size and weight depend on the part's geometry, structure, and the specific aluminum alloy used. If you share your 3D drawings, our experts will promptly and thoroughly review the manufacturability.
Q8. Do you offer a one-stop (turn-key) solution that includes CNC machining and surface finishing?
Yes, we do. To maximize convenience and efficiency for our clients, CASTMAN provides a one-stop solution that includes all necessary post-casting processes. After the initial die casting, parts are precision CNC machined to your required tolerances at our in-house facilities or through our network of vetted partners. We can then proceed with various surface treatments like anodizing, plating, or powder coating, as well as heat treatment for improved strength, and even final assembly. By sourcing the finished part from a single point of contact, clients can avoid the hassle of managing multiple vendors, ensuring consistent quality and reducing overall lead times.
Q9. How do you guarantee the leak-proof performance of parts with internal cooling channels?
Leak-proof integrity is a core quality attribute for our salt-core parts, and we employ a multi-stage validation process to ensure flawless performance. First, during the design phase, we use CAE flow analysis to create a design that minimizes the formation of shrinkage porosity, a potential source of leaks. Second, during casting, we actively use vacuum die casting technology to suppress the formation of gas porosity by removing air from the mold cavity before injection. Finally, and most critically, we conduct 100% leak testing on every part that has a sealing requirement. We use pneumatic or hydraulic pressure to detect even microscopic leaks according to customer specifications, and can perform higher-precision tests like helium leak testing when required to guarantee perfect sealing performance.
Q10. For new mold development, do you provide casting simulation services to prevent problems in advance?
Yes, we consider casting simulation an essential step for every new mold development project. It is a core part of our "Right at the First Time" development philosophy. Using world-class CAE software like FLOW-3D®, we create a 3D simulation of the entire process of the molten metal filling the mold and solidifying. This allows us to analyze the metal flow, temperature changes, and pressure distribution to accurately predict the location of potential defects such as porosity, shrinkage, and misruns. Based on these results, we finalize the optimal gate and overflow system design, eliminating all risk factors before any steel is cut. This minimizes development failures and ensures stable quality in mass production.
Q11. Do you support prototype production for design validation before committing to mass production tooling?
Yes, we actively support various methods of prototype production so that our clients can validate their designs and test performance before investing in mass production tooling. We propose the optimal solution based on the client's requirements, quantity, and budget. Options include CNC machining to create a part from a solid block of the same material, sand casting or plaster mold casting for small batches, or die casting using a soft tool (proto-tool) to test a quality similar to mass production. This allows for early evaluation of assembly, functionality, and durability, which significantly reduces development risks and enhances the perfection of the final mass-produced product.
Q12. How do you manage tool life and maintenance to ensure long-term quality consistency?
The mold is the most critical asset determining die casting quality, so we operate a systematic lifecycle management system for it. From the design stage, we use high-quality, heat-resistant tool steel and apply precise heat and surface treatments to maximize durability. We provide guaranteed shots for every mold and maintain its optimal condition through regular preventive maintenance during production. All maintenance history, including cleaning, coating refurbishment, and replacement of worn parts, is meticulously managed by our system. These efforts ensure that the quality of the first part and the last part remains identical throughout the tool's life, which is the foundation of our stable, high-volume supply capability.
Q13. Do you have a special management plan to minimize porosity, a chronic issue in die casting?
Porosity can be detrimental to the mechanical strength and leak-proof integrity of a die-cast part, so we employ a multi-faceted approach to minimize it. First, through CAE flow simulation, we predict areas where gas could be trapped or shrinkage could occur and implement an optimal mold design to avoid them. Second, during production, we actively apply vacuum die casting to fundamentally suppress the formation of gas porosity by removing residual gases from the mold cavity before injection. Finally, our real-time process monitoring system ensures that the injection speed and pressure of every shot remain uniform. Upon customer request, we can also provide 100% X-ray inspection to guarantee perfect internal quality.
Q14. Assembly precision is very important. What level of precision tolerance can you manage?
While die casting excels at rapidly mass-producing complex shapes, achieving ultra-high precision tolerances in the micron range is difficult with the casting process alone. Understanding this, we offer the most efficient way to achieve the required precision. The die casting process itself meets general tolerances (e.g., ISO 8062 CT5~CT7) according to international standards. However, for areas requiring high precision for assembly with other parts—such as holes, flange surfaces, or bearing seats—we can achieve high-precision tolerances of ±0.02mm or even tighter through post-process CNC machining. We accurately identify the critical functional areas of the product to meet our customer's precision requirements in the most economical way, avoiding over-engineering.
Q15. Are you experienced with international projects? How are global communication and logistics handled?
Yes, CASTMAN has extensive experience successfully executing projects with leading companies worldwide, including in North America, Europe, and Japan. We assign dedicated engineers and sales personnel fluent in English and Japanese to ensure smooth communication with our global clients. All technical documents and reports are provided in the client's language, and we share project progress transparently through regular video conferences. Furthermore, we handle contracts and logistics according to international trade regulations like Incoterms, and can deliver products safely and promptly to your desired location. You can experience CASTMAN's innovative technology and services from anywhere in the world, without language or distance barriers.
Q16. What is the standard lead time from project inquiry to receiving the first prototype (T1) sample?
The standard lead time varies depending on the project's complexity, part size, and mold structure, but we can provide a general timeline. After receiving final drawing approval from the client, mold design and detailed review take about 1-3 weeks, and the actual mold fabrication takes about 4-8 weeks. Once the mold is complete, an additional 1-2 weeks are needed for the first trial shot, production of the T1 sample, and dimensional/internal inspection. Therefore, it typically takes a total of 8 to 12 weeks from project kickoff until the client receives the first prototype. We share the project schedule transparently through close consultation with our clients and do our best to accommodate urgent requests.
Q17. What information do I need to provide to get an accurate quotation?
For a prompt and accurate quotation, it is best to prepare and share the following information. First, a 3D model file (STEP, IGS, x_t, etc.) to understand the part's geometry and a 2D drawing specifying key dimensions and tolerances are essential. Second, please clarify the desired material (e.g., aluminum ADC12, copper C1100). Third, we need the estimated annual usage (EAU) and the minimum order quantity (MOQ) or lot size per order to understand the project's scale. Lastly, if there are any special requirements for post-processing such as CNC machining, surface treatment, heat treatment, assembly, or specific inspection criteria, please include that information. If you send these materials through the 'Contact Us' page on our website, our dedicated expert will review them and contact you immediately.
Contact Us
CASTMAN B-301, Woolim Lions Valley, 168, Gasan digital 1-ro, Geumcheon-gu, Seoul, Korea
Tel : +82-31-351-5022
Fax : +82-31-351-5033
Email : sales@castman.co.kr
Q18. How is our company's technical information and intellectual property (IP) protected?
CASTMAN treats our clients' intellectual property as one of our most important assets, and we operate a very strict security policy to protect it. All new projects begin with the signing of a mutual Non-Disclosure Agreement (NDA) as a fundamental principle. All drawings, technical documents, and data received from clients are stored on an encrypted server, and access is strictly controlled, available only to authorized personnel involved in the project. Furthermore, we conduct regular security training for all employees to emphasize the importance of information protection. You can proceed with your most sensitive and innovative projects with us with complete peace of mind.
Q19. What efforts are you making towards ESG management for sustainable growth?
To fulfill our corporate social responsibility and contribute to a sustainable future, CASTMAN actively practices ESG (Environmental, Social, and Governance) management. (E) Environmentally, we have introduced state-of-the-art electrostatic precipitators to reduce air pollutants and we recycle 100% of the aluminum and copper scrap generated during production to minimize resource waste. (S) Socially, we create a safe and healthy working environment, support employee growth, and pursue co-prosperity with the local community. (G) In terms of governance, we adhere to transparent and ethical management principles to earn the trust of all stakeholders.
Q20. Among numerous suppliers, what is the most decisive reason to choose CASTMAN as a technology partner?
The most decisive reason is that CASTMAN provides clients with the 'key to overcome technological limitations.' Choosing us is not just about buying a part; it means securing the 'unrivaled technical capability' to create products that your competitors cannot replicate. Our world-class Salt Core, aluminum, and copper die casting technologies offer the potential to make your products lighter, stronger, and more efficient. In addition, the close-knit technical support from our experts throughout the entire process—from design to mass production, post-processing, and quality assurance—eliminates development uncertainties and guarantees success. Your most difficult challenge is our greatest opportunity. With CASTMAN, you can turn your imagined products into reality.
Contact
CASTMAN B-301, Woolim Lions Valley, 168, Gasan digital 1-ro, Geumcheon-gu, Seoul, Korea
Tel : +82-31-351-5022
Fax : +82-31-351-5033
Email : sales@castman.co.kr