Why is CNC Machining Chosen for Telecom Aluminum Housings Over Cost-Effective Die Casting?
The reason lies in the fact that manufacturers prioritize product reliability, precision, heat dissipation, shielding effectiveness, and the flexibility to adapt to market changes and design iterations, rather than solely pursuing the lowest per-unit production cost. For production volumes that are typically not in the millions of units, CNC machining offers the best balance of performance, cost, and speed.
Die Casting: Suitable for Mass Production
It requires the creation of expensive, high-strength steel molds (known as “die-casting molds”). Once the mold is developed, the cost per individual part is very low. However, if only a few thousand or even a few hundred units are produced, the mold cost allocated to each part becomes very high, making it uneconomical.
CNC Machining: Suitable for Small to Medium Batch Production
It involves cutting and shaping directly from aluminum plates or blocks, with no mold costs required. For products like telecom equipment that may undergo frequent iterations and where order quantities per batch are not necessarily massive, CNC is often more cost-effective in terms of total cost.
Telecom equipment demands high structural strength and electromagnetic interference (EMI) shielding.
Die Casting:
Advantage: Capable of producing complex, one-piece housings with good strength.
Disadvantage: The material may contain microscopic internal pores, which can compromise mechanical strength and density. This poses a potential risk for telecom equipment that must withstand significant impact or require extremely high reliability.
CNC Machining:
Advantage: Utilizes high-strength aluminum alloy plates (e.g., 6061, 5052), which are inherently dense and uniform, offering excellent and isotropic mechanical properties. With rational structural design, CNC-machined housings can be highly robust and durable.
Seamless Integration: It allows for the direct machining of precise cooling fins and sealing grooves into the housing walls, which is crucial for thermal management and outdoor water resistance.