This project involves the manufacture of custom A356.0-T6 aluminum castings for a long-term Australian customer in the automotive modification market.
The casting set was developed for a DANA 44 differential assembly and includes a differential housing, differential hat, axle housing, and bearing caps. All components are manufactured according to the customer’s approved drawings and technical requirements.
Complete DANA 44 Differential Casting Set
The project includes four matching aluminum casting components:
- DANA 44 Differential Housing
- DANA 44 Differential Hat
- DANA 44 Axle Housing
- DANA 44 Bearing Cap
These parts are designed to work together within the same differential assembly. The bearing caps are used in pairs, so their order quantity is normally double that of the other three components.
In one subsequent production order, we manufactured 70 differential housings, 70 differential hats, 70 axle housings, and 140 bearing caps.
Material: A356.0-T6 Aluminum Alloy
The specified material for this project is A356.0-T6 aluminum alloy.
A356-T6 is widely used for automotive structural components because it provides good castability, reliable mechanical properties, and a favorable strength-to-weight ratio after T6 heat treatment. It is suitable for differential housings and related components where structural integrity and weight reduction are both important.
Shell Mold Casting and Tooling Development
These components are manufactured by aluminum shell mold casting. This process was selected based on the product structure, tooling budget, order quantity, and required casting quality.
During the development stage, the customer updated several drawing details according to assembly requirements. We supported the project through casting pattern development, drawing review, mould modification, prototype confirmation, and subsequent batch production.
The differential housing required casting clearance and core adjustments, while other components were also refined during the development process. These modifications helped ensure that the final castings matched the latest approved drawings and assembly requirements.
Learn more about our custom aluminum casting manufacturing capabilities.
Production Inspection
After casting, the parts are trimmed, cleaned, and inspected before packing. Product weight checks are carried out during production as an additional reference for casting consistency and packing arrangement.
The finished castings are checked against the approved drawings before shipment. The products are then packed in suitable export packaging to protect the different shapes and sizes of the castings during transportation.
From Development to Stable Repeat Production
This project demonstrates our ability to support custom aluminum casting projects from drawing review and tooling development through casting production, inspection, packing, and repeat orders.
For custom aluminum differential castings, housings, bearing caps, axle components, and other automotive metal parts, we manufacture according to drawings, samples, 3D files, material requirements, and production quantities.
You can also explore our metal casting capabilities for automotive and industrial components.
