In the field of precision manufacturing, the accuracy and stability of mold accessories and CNC tooling directly determine product yield and production efficiency. With years of in-depth experience in precision machining, Zorapid specializes in custom high-difficulty and high-precision mold components and CNC tooling. Centering on five-axis linkage technology, micron-level precision control and independent full-process craftsmanship, we resolve industry pain points including thin-wall deformation, deep cavity machining difficulties and irregular positioning issues, emerging as a preferred partner in precision manufacturing.
Technology & Craftsmanship: Full-chain precision process, micron-level precision implementation
Zorapid adopts a standardized six-stage process: Roughing → Semi-finishing → Heat Treatment → Finishing → Superfinishing → Surface Treatment. Strict parameter control is enforced in every procedure to guarantee accuracy and stability from the source, fully meeting demands for high-precision mold components and CNC tooling.
Five-axis linkage CNC Machining (Core Technology)
Equipped with imported five-axis linkage machining centers with spindle speed up to 30000rpm, it enables multi-surface machining in one clamping to eliminate repeated clamping errors. Positioning accuracy reaches ±0.005mm, ideal for complex cavities, special-shaped tooling and thin-walled parts processing.
Precision Grinding Process
Centerless Grinding: Applied to shaft-type parts such as guide pins and ejector pins, diameter tolerance controlled within ±0.001mm, surface roughness Ra≤0.2μm.
Jig Grinding: Capable of machining sharp corners, narrow grooves and complex profiles unavailable via conventional grinding, sharp corner accuracy up to R≤0.02mm.
Wire EDM + EDM Machining
For high-hardness materials (HRC58-62), narrow slits (≤0.1mm) and deep cavity structures, we adopt wire cut EDM with accuracy of ±0.002mm and EDM machining. Zero cutting force effectively prevents workpiece deformation and ensures high precision of intricate features.
Precision Lapping & Mirror Polishing
Gradual lapping with assorted sandpapers and polishing paste lowers surface roughness from Ra0.8μm down to below Ra0.1μm. Electrolytic polishing is applied for medical and food-grade parts, achieving 10000-grit mirror finish with excellent corrosion resistance and easy demolding performance.
Detailed Technical Analysis
Thin-Wall Part Machining (Industry Pain Point)
Difficulties: Wall thickness ≤0.8mm. Cutting force easily causes deformation, dimensional deviation and surface chatter marks.
Zorapid Solutions
Clamping: Custom flexible vacuum chucks plus silicone buffer pads disperse clamping force to avoid clamping damage and deformation.
Process: High-speed five-axis milling at 25000rpm spindle speed and 0.05mm/rev feed rate. Layered cutting with small depth of cut (0.01-0.03mm) minimizes thermal deformation.
Compensation: Real-time temperature compensation system corrects micron-level errors caused by ambient temperature changes.
Deep Cavity & Narrow Groove Machining (Industry Pain Point)
Difficulties: Depth-to-width ratio ≥10:1. Tools are prone to vibration and breakage, sharp corner finishing at the bottom is difficult, and poor chip evacuation leads to surface scratches.
Zorapid Solutions
Cutting Tools: Imported ultra-fine cemented carbide tools (φ0.3-φ2mm) paired with high-rigidity tool holders to effectively reduce vibration.
Processing Technology: High-pressure coolant chip removal at 70bar pressure, five-axis side milling layered machining. Leave 0.05mm finishing allowance at the bottom, achieving sharp corner accuracy R≤0.02mm.
Simulation: UG tool path simulation avoids collisions in advance and optimizes cutting routes.
Special-shaped & Hard-to-position Tooling Machining (Industry Pain Point)
Difficulties: Irregular profiles tend to shift when clamped by conventional vices, resulting in large repetitive positioning errors and poor machining consistency.
Zorapid Solutions
Fixtures: Custom quick-change fixtures combined with positioning pins, V-blocks and vacuum suction, repetitive positioning error ≤±0.005mm.
Datum: Unified datum for design, machining and inspection. Adopt 3D scanning comparison to guarantee geometric tolerances: flatness ≤0.005mm/100mm, perpendicularity ≤0.003mm.
What others cannot do, we can. Conquer industry limits and break through technical barriers.
Zorapid focuses on high-difficulty, high-precision and high-complexity customized machining, undertaking extreme processing demands beyond peers’ capabilities. Below are our core breakthrough fields:
Extreme Thin-wall Machining (Wall Thickness: 0.3-0.8mm)
Industry bottleneck: Parts thinner than 1mm are prone to deformation with high scrap rate, which most manufacturers refuse to take.Zorapid capability: Stably process 0.3mm thin-wall parts in aluminum alloy and stainless steel. Flatness ≤0.005mm, zero deformation and no chatter marks, mass production yield rate ≥99%.
Ultra-deep Cavity Machining (Depth-width Ratio 15:1, Depth Over 100mm)
Industry bottleneck: Depth-width ratio over 8:1 causes severe tool vibration and frequent tool breakage, making complete bottom sharp corner finishing impossible.
Zorapid capability: Adopting five-axis linkage and high-pressure cooling system, we steadily machine deep cavities with 15:1 depth-width ratio and 120mm depth. Bottom corner radius R≤0.02mm, surface roughness Ra≤0.4μm.
Micro Feature Machining (φ0.3mm Micro Holes, R0.05mm Sharp Corners)
Industry bottleneck: Micro holes below φ0.5mm are easy to deflect and clog, sharp corners tend to chip off with unstable precision.
Zorapid capability: Combined wire EDM and EDM machining enables stable fabrication of φ0.3mm through holes & blind holes with concentricity ≤0.003mm. Intact R0.05mm sharp corners, perfectly suitable for semiconductor and medical precision components.
High Hardness Material Machining (HRC60-65 Quenched Steel / Cemented Carbide)
Industry bottleneck: High-hardness materials are difficult to machine with rapid tool wear, prone to surface burning and cracking.
Zorapid advantage: Equipped with CBN cutters and five-axis high-speed cutting technology, we process quenched steel up to HRC65 with zero surface burning and cracks, maintaining stable dimensional tolerance within ±0.002mm.
Applicable Materials: Full range coverage, precise material selection on demand
Zorapid processes a full spectrum of materials including mold steel, stainless steel, aluminum alloy, titanium alloy, superalloy and engineering plastics. We select optimal materials precisely based on working requirements such as wear resistance, heat resistance, corrosion resistance and high strength. All raw materials are genuine and traceable, with no recycled materials adopted.
1. Mainstream Mold Steel
| Grade | Hardness | Characteristics | Applications |
|---|---|---|---|
| SKD61 (4Cr5MoSiV1) | HRC 48-52 | Heat-resistant, thermal fatigue resistant, low deformation | Injection mold cores, ejector pins, die casting mold components |
| SKH51 (High Speed Steel) | HRC 62-65 | High hardness, high wear resistance, good red hardness | Stamping punches, high-frequency ejector pins, wear blocks |
| S136 / STAVAX | HRC 48-52 | Corrosion-resistant, excellent mirror polishability | Medical / food-grade molds, transparent part mold cores |
| DC53 | HRC 58-62 | High toughness, high wear resistance | Ejector pins, mold cores, complex stressed components |
| SUJ2 (GCr15) | HRC 58-62 | Wear-resistant, dimensionally stable | Guide pins, guide bushes, bearing components |
Aluminum Alloy / Titanium Alloy (Lightweight & High Strength)
Aluminum Alloy (6061-T6 / 7075-T6)
Lightweight, easy to machine and excellent thermal conductivity. Ideal for CNC tooling, fixtures and new energy mold parts.
Titanium Alloy (Ti-6Al-4V)
High strength, outstanding corrosion and heat resistance. Perfect for aerospace and medical precision tooling.
Superalloys & Engineering Plastics (For Special Working Conditions)
Superalloy (Inconel 718)
High temperature resistance, corrosion resistance and superior strength, suitable for aero-engine tooling and high-temperature mold components.
Engineering Plastics (PEEK / Nylon)
Good insulation, wear resistance and corrosion resistance, widely used in semiconductor and insulated tooling parts.
Case Analysis: Practical Application, Proven Precision Strength
Case 1: Semiconductor Temperature Control Cover Screw Tooling (Nylon + Aluminum Alloy)
Customer Pain Points
60×60×10mm square part with a φ38.8mm four-lobed special-shaped central cavity and wall thickness below 5mm. Nylon material tends to warp due to moisture absorption. Symmetry deviation of four arc segments shall be within 0.05mm, with a batch quantity of 50 pieces.
Zorapid Solutions
Material Treatment
Dry nylon at 80℃ for 8 hours to eliminate internal stress; adopt 6061-T6 aluminum alloy with hard anodizing treatment.
Processing Technology
One-step five-axis integrated forming, layered cutting at 0.2mm per layer with 0.1mm finishing allowance left. Climb milling plus air blowing effectively reduce edge tearing.
Achieved Precision
Symmetry deviation of four arc segments: 0.03mm; hole concentricity ≤0.02mm; flatness ≤0.008mm, 100% pass rate in mass production.
Case 2: New Energy Battery Tray Thin-Wall Tooling
(6061-T6 Aluminum Alloy, Wall Thickness: 0.5mm)
Customer Pain Points
120×80×20mm thin-wall frame with 0.5mm wall thickness. Required flatness ≤0.005mm with zero deformation, used for battery tray positioning tooling.
Zorapid Solutions
Clamping: Custom vacuum suction cup with silicone cushion for even adsorption without local stress.
Process: Five-axis high-speed milling at 28000rpm, layered cutting with small depth of cut plus real-time temperature compensation.
Finished Precision
Flatness reaches 0.004mm, wall thickness tolerance ±0.003mm, no deformation or chatter marks. Delivery lead time: 3 days.
Medical Interbody Fusion Cage Mold Insert (S136 Stainless Steel, HRC50)
Customer Pain Points
It features complex cavities with depth-to-width ratio of 12:1 and sharp bottom corners of R0.05mm. Corrosion resistance and 10000-grit mirror polishing are required for medical implant molds.
Zorapid Solutions
Process: Five-axis roughing → Heat treatment → EDM corner finishing → 10000-grit mirror polishing.
Precision: Cavity dimensional tolerance ±0.003mm, intact sharp corners without chipping, surface roughness Ra≤0.08μm, fully compliant with corrosion resistance standards.
Quality Assurance: Full-process control, micron-level quality guarantee
Zorapid has established a full-chain quality control system covering raw material sourcing, machining, inspection, finished product delivery and after-sales service. Certified with ISO9001, IATF 16949 and AS9100D, we conduct 100% full-dimensional inspection on every product to prevent defective goods from delivery.
Machining Process Control
Equipment: Five-axis machining centers, precision grinders, wire EDM and other facilities are calibrated regularly. All machines preheat for 30 minutes daily and undergo maintenance every 500 hours to maintain stable precision.
Process: First article inspection for every procedure, in-process random sampling, real-time monitoring of critical dimensions, with all parameter records fully traceable.
Staff: Operated by senior engineers with over 10 years of experience. Standard operating procedures are strictly followed to minimize human errors.
Finished Product Inspection Control
Equipped with Zeiss CMM (accuracy: 0.001mm), height gauges, roughness meters, optical microscopes and other precision testing instruments. We conduct full-dimensional inspections on dimensions, geometric tolerances, surface roughness, hardness and other indicators, and issue official inspection reports.
After-sales Warranty Commitment
We provide lifelong technical support for all products together with 12-month quality warranty. Free repair or replacement is available for non-artificial damages, with full-time service response to eliminate your worries.
VII. Delivery Speed: Efficient Production Management, On-time Fast Delivery
Zorapid adopts modular production, flexible scheduling and full-process progress visualization to balance precision and efficiency, meeting urgent orders without delaying client production schedules.
1. Delivery Lead Time Commitment
- Standard parts: In stock for immediate shipment within 24 hours.
- Conventional custom parts: Delivery within 3-5 working days.
- High-precision & complex parts: Delivery within 7-10 working days.
- Urgent orders: 24-hour response, expedited delivery within 48 hours via priority customized channel.
Efficient Production Guarantee
Production Capacity: Multiple five-axis machining centers, precision grinders and wire EDM machines operate in parallel with sufficient output to fulfill mass orders.
Supply Chain: Adequate safety stock of raw materials is always available. We maintain strategic cooperation with core suppliers to ensure material arrival within 72 hours and avoid production shutdown caused by material shortage.
Transparent Progress: Production updates are delivered three times weekly with real-time processing progress synchronized, enabling clients to check production status anytime.
Benefits of Choosing Zorapid: Beyond Precision, Delivering Greater Value
Technical Advantages: We accomplish what others cannot
We focus on ultra-challenging extreme machining. Equipped with five-axis linkage and self-developed processes, we solve tough processing difficulties including thin walls, deep cavities, micro features and high-hardness materials. Zorapid reliably fulfills orders beyond our peers’ capability.
Precision Advantages: Stable micron-level accuracy with industry-leading yield rate
Full-process precision control ensures stable dimensional tolerance from ±0.002mm to ±0.005mm and surface roughness Ra≤0.2μm. Mass production yield reaches over 99%, cutting rework costs and boosting production efficiency.
Material Advantages: Traceable genuine materials, 3-5 times longer service life
We adopt full-range authentic raw materials without recycled materials. Stable heat treatment hardness makes our parts last 3 to 5 times longer than ordinary products, lowering replacement frequency and offering superior long-term cost performance.
Delivery Advantages: Fast lead time to avoid production delay
Standard orders delivered within 3-5 days, urgent orders finished within 48 hours via priority channel. Fully transparent and traceable progress effectively solves urgent order demands and prevents production line downtime losses.
Service Advantages: One-stop customized service with hassle-free support
Full-range services covering drawing optimization, material selection, machining, inspection, delivery and after-sales warranty. Dedicated one-on-one technical consultants provide 24/5 instant response to resolve all technical and production issues.
Cost Advantages: Direct factory supply with high cost performance
In-house production eliminates middleman markup with favorable bulk order pricing. High yield rate and long service life greatly reduce rework and replacement expenses for lower overall costs.
Summary: Zorapid — Your Top Choice for Custom Precision Mold Components & CNC Tooling
Centered on micron-level accuracy, advanced difficult machining capability, full-chain quality control, fast delivery and one-stop services, Zorapid specializes in precision mold parts and CNC tooling manufacturing. We solve core industry pain points and help clients upgrade product precision, yield rate and production efficiency.
We deliver customized precision machining solutions for semiconductor, medical, aerospace, new energy vehicle, 3C electronics and mold manufacturing industries. excel at projects others cannot handle, and perfect what others can achieve.
FAQ
What is the minimum machining precision you can achieve?
Our standard dimensional tolerance is ±0.005mm, and critical dimensions can reach ±0.002mm. The surface roughness is Ra≤0.1μm, and geometric tolerances including flatness and perpendicularity are within ≤0.003mm.
Can you guarantee the yield rate of high-difficulty thin-wall and deep-cavity parts?
Yes. For thin-wall parts above 0.3mm and deep-cavity parts with depth-width ratio up to 15:1, we adopt custom fixtures, five-axis high-speed milling and real-time temperature compensation technology. The mass production yield rate reaches over 99%. Trial samples are available for verification.
How long is the delivery lead time? Can urgent orders be expedited?
Regular custom parts take 3-5 days, high-difficulty parts 7-10 days, and standard parts can be shipped out within 24 hours. Priority service is available for rush orders with delivery within 48 hours, and the whole production progress is fully transparent and traceable.
