Die Casting Solutions
Low-Pressure & High-Pressure · Cell Automation · Configured to Your Part
At A Glance
Operations Performed
Full Specifications
HPDC Cell — Servo Cold-Chamber Sprayer & Extractor (FRZ Series)
| Specification | FRZ-02 | FRZ-04 | FRZ-06 | FRZ-08 | FRZ-10 |
|---|---|---|---|---|---|
| Suitable for HPDC machine (T) | 180–450 | 500–850 | 1000–1300 | 1600–2000 | 2500–3000 |
| Spray nozzles (fixed mould) | 14 pcs | 18 pcs | 22 pcs | 26 pcs | 30 pcs |
| Spray nozzles (moving mould) | 14 pcs | 18 pcs | 22 pcs | 26 pcs | 30 pcs |
| Air-source pressure (kgf/cm²) | 6 | 6 | 6 – 7 | 6 – 7 | 6 – 7 |
| Effective travel — lift / X-axis (mm) | 735 | 800 | 3,300 | 4,000 | 4,300 |
| Spray head width (mm) | 450 | 500 | 690 | 850 | 930 |
| Spray cycle time (sec) | 3 – 4 | 3 – 4 | ≤5 | ≤5 | ≤5 |
| Power supply | 3-Phase 380V / 50 Hz | 3-Phase 380V / 50 Hz | 3-Phase 380V / 50 Hz | 3-Phase 380V / 50 Hz | 3-Phase 380V / 50 Hz |
HPDC Cell — Hydraulic Trim Press (Edge Cutting / Deflashing)
| Specification | FRV-02 | FRV-04 | FRV-06 | FRV-08 | FRV-10 | FRV-12 |
|---|---|---|---|---|---|---|
| Suitable for HPDC machine (T) | 125–400 | 500–800 | 1000 | 1600 | 2000–2500 | 3000–4000 |
| Pouring capacity (kg) | 0.5–5 | 2.5–8 | 12–15 | 15–25 | 25–50 | 50–70 |
| Pouring accuracy | ±1% | ±1% | ±1% | ±1% | ±1% | ±1% |
| Crucible diameter (mm) | ≥480 | ≥480 | ≥800 | ≥800 | ≥1000 | ≥1100 |
| Ladle depth (mm) | ≤450 | ≤450 | ≤450 | ≤450 | ≤450 | ≤450 |
| Arm servo motor (kW) | 1.5 | 1.5 | 3.0 | 3.0 | 3.0 | 3.0 |
| Power capacity (kVA) | 1.5 | 1.5 | 3.0 | 3.0 | 3.0 | 3.0 |
| Pouring cycle time (sec) | 6–8 | 6–8 | 8 | 10 | 12 | 15 |
HPDC Cell — Hydraulic Trim Press (Edge Cutting / Deflashing)
| Specification | FRZQB-20T | FRZQB-40T | FRZQB-60T | FRZQB-80T | FRZQB-100T |
|---|---|---|---|---|---|
| Mould closing force (T) | 20 | 40 | 60 | 80 | 100 |
| Mould opening force (T) | 6 | 8.1 | 8.4 | 10 | 12.5 |
| Mould column spacing (mm) | 940×840 | 1110×910 | 1230×1020 | 1325×1075 | 1430×1130 |
| Mould opening stroke (mm) | 700 | 800 | 1000 | 1000 | 1100 |
| Max die opening (mm) | 1000 | 1100 | 1200 | 1500 | 1400 |
| Die closing speed (mm/s) | 200 | 200 | 200 | 200 | 200 |
| Die opening speed (mm/s) | 120 | 120 | 120 | 120 | 120 |
| Oil pump motor (kW) | 7.5 | 7.5 | 11 | 15 | 15 |
Standard Features Optional Equipment
Standard Features
- Full-servo architecture across ladle, spray, and extract axes
- Japan-grade precision servo motor and reducer (drive train)
- Japan OMRON PLC + handheld touch-screen HMI
- Japan NSK precision bearings on all primary axes
- Germany Rexroth linear guide rails (steel-belt protection)
- Germany Rost high-precision planetary reducer
- IP67 protection grade on all field-exposed parts
- Diversified standby modes (auto + manual switching)
- Fault-code display and self-diagnostics
Optional Equipment
- Six-axis ABB anthropomorphic extractor (cell-level integration)
- Modular / profiling / tubular spray-tool quick-changers
- Quantitative pouring furnace (insert into ladling line)
- Closed cooling tank with stainless tray & auto-drain
- Six-station forced-air cooling carousel
- Photoelectric inspection station (post-trim quality check)
- Stainless steel conveyor between cell stations
- Laser marking station (traceability)
- Plunger lubrication / mould-temperature controller integration
Typical Workpieces
Frequently Asked Questions
What is the difference between LPDC and HPDC?
Low-Pressure Die Casting (LPDC) uses a holding furnace below the die and pushes molten metal upward into the mould under low gas pressure — ideal for thick-walled aluminium parts like cylinder heads and wheels where porosity must be minimal. High-Pressure Die Casting (HPDC) injects molten metal at very high velocity and pressure into a steel die — used for thin-walled, high-volume parts like gearbox housings, crankcases, and electronics enclosures.
Does Stallion supply the HPDC machine itself?
Stallion configures and integrates complete HPDC cell automation around the customer's die casting machine — including servo ladlers, multi-axis sprayers, extractors, trim presses, and CNC deburring stations. For the die casting machine itself, Stallion works with established HPDC machine partners to deliver a turnkey cell. Talk to our engineering team to scope your full installation.
What HPDC machine tonnage range can the RZ peripherals support?
The FRZ-series HPDC peripheral range covers HPDC machines from 180 tonnes to 4000 tonnes — across sprayers (FRZ-02 to FRZ-10), servo ladlers (FRV-02 to FRV-12), and trim presses (FRZQB-20T to FRZQB-100T). The cell is sized to the die casting machine and part-mass envelope.
How is the spray, ladle, and extract cycle synchronised?
All axes run under a unified PLC controller with full servo drives, so spray-extract-ladle sequences are time-locked to the die casting machine's cycle signal. Pouring accuracy holds to ±1%, spray-head positioning to ±0.05 mm, and the entire cell can be operated by a single technician via a handheld touch-screen HMI.
Why is the Stallion HPDC cell superior to competitor offerings?
The cell is built around a full-servo drive train — not the legacy pneumatic-plus-electric mix — which delivers higher running speed, lower failure rate, longer braking life, and quieter operation. Critical components including servo motors, bearings, PLCs, pneumatics, and linear guides are built around internationally proven names across Japan, Germany and Europe — Panasonic, OMRON, NSK, SMC, Rexroth, Rost — for sustained accuracy and long service life in heavy-duty foundry conditions.