Customer Cases

As automotive interiors continue to evolve toward digital and intelligent cockpit design, multi-screen displays have become a standard feature in premium vehicles. Among them, the Triplex (three-in-one) curved display requires exceptionally high structural rigidity, dimensional stability, surface flatness, and coating quality.

With extensive experience in aluminum, zinc, and magnesium alloy die casting, our team provides stable mass-production capability for complex, large-format display housings used in automotive applications.

Below is a detailed case study of one of our representative projects.

Triplex Screen (Curved Surface) Die-Cast Display Housing

Category: Automotive Display Aluminum Die-Cast Enclosure

Base Material: Aluminum alloy (zinc/magnesium optional)

Process: High-precision die casting + CNC machining + piano lacquer finishing

Application: Intelligent cockpit display systems / central control display module

1. Technical Parameters

2. Engineering Highlights & Technical Challenges

2.1 Large Size + Curved Geometry: Challenges in Die Filling & Deformation Control

At 900 mm in length, this display housing falls into the category of large-span structural die-cast components, which tend to exhibit: 

Warpage and deformation

Inconsistent curvature

Surface flow lines or cold shuts

Stress concentration

By optimizing gating design, cavity temperature control, and metal flow simulation, we achieved uniform filling and minimized structural deformation.

2.2 Flatness Requirement: 0.7 mm → 0.3 mm After CNC Machining

Flatness is critical for display assembly and bonding.

We implemented:

High-rigidity die-casting process

Full-surface CNC machining using dedicated fixtures

Multi-point datum reference system

Predictive deformation compensation

This ensures final flatness can be controlled within 0.3 mm, meeting strict Tier-1 automotive standards.

2.3 Piano Lacquer (Glossy Black) Coating: High-End Surface Requirements

Piano lacquer finishing is extremely sensitive to any imperfections on the substrate. Even minor issues such as:

Micro-pores

Milling marks

Tiny surface depressions

will become obvious after coating.

To achieve a flawless mirror-like finish, we applied:

High-polish tool cavity

Secondary deburring + ultrasonic cleaning

Clean-room electrostatic coating

Controlled temperature curing profile

The final result delivers deep black, high-gloss finishing with no orange peel or visual defects.

2.4 Tooling Design for Large-Format Die Casting

To ensure stable, repeatable mass production, the mold was designed with:

Multiple slider/core pulling mechanisms

Balanced runner system

Independent oil-temperature control circuits

Structural stiffening ribs

CAE simulation for flow, cooling, and stress

These measures resulted in:

Consistent curvature

Minimal warpage

Smooth surface quality

Long mold life and stable cycle time

3. Manufacturing Process Flow 

Tooling design & CAE simulation

High-pressure die casting

Automatic + manual deburring

CNC machining (datum + assembly surfaces)

Surface finishing (blasting / powder / piano lacquer)

Appearance and dimensional inspection

Assembly validation

Packaging and shipment

4. Quality Control Standards

We perform comprehensive inspections using professional equipment:

CMM dimensional measurement

3D surface scanning (curvature & flatness)

Surface roughness testing

Coating adhesion (cross-hatch test)

High/low-temperature cycling

AQL cosmetic inspection

This ensures every batch meets automotive-grade performance.

5. Application Fields

This die-cast display housing is suitable for:

Automotive intelligent cockpit display systems

Central control displays and instrument cluster housings

EV interior structural parts

High-end consumer electronic housings

Customized curved display enclosures

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These help customers find your case easily via Google search.

7. Conclusion

Triplex curved display housings represent one of the most challenging categories in automotive die casting due to their size, curvature, and appearance requirements. Leveraging our advanced tooling design, precision machining, and high-spec finishing capabilities, we successfully achieved stable mass production for this project.

We provide end-to-end solutions including:

Product design support

Mold development

Rapid prototyping

Mass production

Surface finishing & assembly

Feel free to contact us for evaluation of drawings or new project development.