How are robot die castings and molds cleverly designed to meet the multi-functional integration needs of robots?
Publish Time: 2025-12-30
In the precision structures of modern industrial robots, collaborative robots, and even service robots, robot die castings and molds play a dual role as both the "skeleton" and the "nerve pathway." Faced with the stringent requirements of robots for lightweight design, high rigidity, compact layout, and multi-functional integration, traditional machining or welding structures are no longer sufficient. Structural components manufactured using advanced die casting processes, with their near-net-shape, complex internal cavities, high dimensional accuracy, and excellent mechanical properties, have become the key carrier for achieving high-level multi-functional integration in robots. Their ingenious design is not only reflected in optimized shape but also extends to the microscopic level of internal flow channels, insert integration, and functional compositing.1. Integrated Structure: Reducing the Number of Parts and Improving System RigidityCore components such as robot joints, bases, and arms need to support motors, reducers, encoders, cables, and cooling systems within a limited space. Assembling multiple parts not only increases assembly errors and the risk of loosening but also reduces overall rigidity, affecting positioning accuracy. Die casting can transform a module originally composed of 5-10 parts into a single, complex shell in a single process. For example, a die-cast robot arm can integrate a motor mounting flange, harmonic reducer positioning stops, cable perforations, and heat dissipation fins, significantly reducing bolt connections, improving structural compactness and dynamic response performance, while also reducing vibration and noise.2. Built-in Flow Channels and Cavities: Integrating Cooling, Wiring, and SensingHigh-performance robots generate significant heat during continuous operation, especially at high-load joints. Advanced die castings utilize embedded cooling water channels within the mold, directly forming closed liquid cooling channels within the casting. This allows the coolant to flow closely to the heat source, achieving significantly higher heat dissipation efficiency than external air cooling. Simultaneously, stainless steel or plastic conduits can be pre-embedded during die casting as cable protection channels, preventing cable wear during movement. Some designs also include pre-reserved sensor mounting holes or optical windows for integrating torque, temperature, or vision modules. This "structure as function" design philosophy transforms die castings from passive load-bearing components into integral parts of intelligent electromechanical systems.3. Lightweight Topology Optimization: Balancing Strength and Energy Consumption ControlRobots are extremely sensitive to weight—for every kilogram increase in weight, motor power consumption and inertia rise. Die-cast parts utilize CAE simulation-driven topology optimization to remove redundant material in non-critical load-bearing areas, creating a biomimetic honeycomb or hollow reinforcing rib structure. This achieves a 20%–30% weight reduction while maintaining or even improving rigidity.4. High-Precision Mating Surfaces and Insert Integration: Ensuring Assembly ReliabilityRobots require extremely high repeatability and positioning accuracy. Key mounting surfaces of die-cast parts are locally thickened and subsequently precision-machined to ensure flatness and concentricity. Simultaneously, steel threaded sleeves, bearing seats, or grounding terminals can be pre-embedded during die-casting to address the issues of easy stripping and poor wear resistance of aluminum alloy threads. This composite structure of "metal inserts + aluminum substrate" retains the advantages of lightweight design while meeting the requirements for high-strength connections and electrical grounding.5. Surface Treatment and Electromagnetic Compatibility Design: Adapting to Complex Working ConditionsTo cope with factory oil, moisture, or EMC interference, die-cast parts often undergo micro-arc oxidation or conductive anodizing treatments to form a surface layer with high hardness, corrosion resistance, and electromagnetic shielding capabilities. Some collaborative robot shells even integrate conductive coatings to prevent leakage of internal high-frequency signals, ensuring electromagnetic safety in human-robot co-working environments.The ingenious design of robot die castings and molds is essentially a systems engineering project that deeply integrates mechanics, thermals, electrical systems, and manufacturing processes. It is no longer just "a single part," but a multifunctional platform integrating load-bearing, heat dissipation, wiring, shielding, and sensing. It is this highly integrated die-casting structure that allows robots to achieve higher performance and reliability in smaller size and lower energy consumption, becoming an indispensable "invisible engine" in the era of intelligent manufacturing.
