Communication equipment hardware solutions

Die casting solutions for communication equipment hardware

Communication equipment (such as 5G base stations, routers, switches, antennas, etc.) has extremely high requirements for the lightweight, heat dissipation, electromagnetic shielding (EMI), and weather resistance of hardware structural components, while die casting (especially aluminum alloy and magnesium alloy die casting) can meet these needs. The following are die casting solutions and key technical points for communication equipment hardware.

1. Core Application Areas

(1) 5G base station equipment

Antenna housing (Aluminum alloy die casting, combining lightweight and signal penetration).

Filter cavity (High-precision die casting, reducing signal interference).

Heatsink/housing (High thermal conductivity aluminum alloy, optimized heat dissipation structure).

(2) Network communication equipment (routers, switches)

Metal housing (Die-cast aluminum + conductive coating, improves EMI shielding).

Heat sink fins (Integrated die casting, enhances heat dissipation efficiency).

Mounting bracket (Magnesium alloy die casting, weight reduction + high strength).

(3) Radio frequency devices (RRU, AAU)

Radio frequency cavity (Aluminum alloy die casting, ensuring signal stability).

Connector housing (Zinc alloy die casting, high precision + plug resistance).

(4) Outdoor communication cabinets/chassis

Waterproof housing (Die-cast aluminum + sealing structure, IP67 protection).

Anti-vibration bracket (Magnesium alloy or high-strength aluminum alloy).

2. Material Selection

3. Key Process Optimization

(1) High-precision die casting (±0.05mm tolerance)

Suitable for Filter cavity, radio frequency connector , reducing signal loss.

Using In-mold trimming + CNC machining , ensuring dimensional accuracy.

(2) Vacuum die casting (reducing pores)

Improve Radio frequency cavity density, avoid signal interference.

Suitable for High thermal conductivity heat sink , reducing thermal resistance.

(3) Insert die casting (metal + plastic/ceramic)

Metal housing embedded with plastic insulation layer (such as antenna cover).

Heat dissipation module embedded heat pipe (Improve heat transfer efficiency).

(4) Semi-solid die casting (SSM)

Reduce internal defects, suitable for High-strength aluminum/magnesium alloy structural components.

4. Surface Treatment Technology

5. Industry Challenges and Solutions

6. Typical Application Cases

✅ Huawei 5G base station antenna housing: High-strength aluminum die casting + conductive oxidation, combining lightweight and signal stability.

✅ Ericsson RRU heat sink: Vacuum die-cast aluminum + embedded heat pipe, 20% temperature reduction.

✅ Cisco switch housing: Die-cast aluminum + EMI shielding coating, reducing signal interference.

✅ Nokia outdoor communication cabinet: Die-cast aluminum + IP67 sealing structure, dustproof and waterproof.

7. Future Trends

🔹 Lighter and stronger: Magnesium alloy or carbon fiber reinforced die-cast aluminum (suitable for portable devices).

🔹 Higher frequency support: Low dielectric loss materials (such as high-purity aluminum) for 6G communication.

🔹 Intelligent production: AI real-time control of die-casting parameters to improve yield.

🔹 Green manufacturing: Recycled aluminum/magnesium alloy + environmentally friendly surface treatment.

Summary

The core requirements for die-casting of communication equipment hardware are:

✔ Lightweight (Magnesium alloy/high-strength aluminum)

✔ Heat dissipation optimization (High thermal conductivity aluminum + vacuum die casting)

✔ EMI shielding (Conductive oxidation/plating)

✔ Weather resistance (Anodizing + fluorocarbon coating)

Recommended process combinations:

5G base station housing → High-strength aluminum + vacuum die casting + conductive oxidation

Router housing → Die-cast aluminum + EMI spray coating

Outdoor communication cabinet → Die-cast aluminum + IP67 sealing + fluorocarbon paint

Companies can choose the appropriate solution based on product needs to improve performance and competitiveness.