OEM Aluminum Motorcycle Intake
Manifold Manufacturer

Step 1: Design Engineering & Flow Simulation

Before production, the internal geometry is paramount. Our engineers use Mold Flow Analysis to simulate both the molten aluminum filling and the internal airflow path. We optimize the gate locations to minimize turbulence and design the core box structure to ensure the sand core remains stable during high-pressure injection. This prevents core shifting, which can cause uneven wall thickness.

Step 2: Precision Shell Core Making (The Critical Step)

Unlike simple covers, intake manifolds are hollow. To form the complex, curved internal runners, we utilize our fleet of 27 Shell Core Machines. · Coated Sand Process: We use high-quality resin-coated sand to create the internal "negative" of the manifold. · Curing & Hardening: The sand is heated to form a rigid, high-strength core with a smooth surface finish. · Why It Matters: This process determines the Roughness (Ra) of the manifold's inner wall. A smoother core means less air resistance and better fuel atomization for the engine.

Step 3: Material Melting & Spectrometer Verification

We strictly control the metallurgical properties. We melt high-grade aluminum ingots (typically ADC12 or A356 ) in our furnaces. Before casting, a sample from every batch is analyzed using a German Spectro Spectrometer. We verify the Silicon (Si) content for fluidity and Iron (Fe) content to prevent sludge, ensuring the manifold can withstand engine vibration and thermal cycling.

Step 4: Casting Process (HPDC / LPDC)

For High Volume: We use High-Pressure Die Casting (8 Machines). The aluminum is injected The sand core is placed inside the steel mold, and the casting process begins. · at high speed, filling the thin walls around the sand core instantly. · For High Density: We use Low-Pressure Die Casting (26 Machines). The metal fills the mold gently from the bottom up, creating a dense, non-porous structure ideal for heavy-duty applications.

Step 5: Core Knockout & Shot Blasting

Once the metal solidifies, the part is removed, and the internal sand core is broken down and shaken out through vibration. The raw casting then enters our Shot Blasting chamber. High-velocity steel shots remove surface oxides, flash, and any remaining sand particles, leaving a clean, uniform matte finish on both the exterior and the critical internal runners.

Step 6: Precision CNC Face Milling

A manifold is useless if it leaks vacuum. We transfer the castings to our workshop of 125 CNC Machining Centers. · Flange Flattening: We perform single-pass face milling on the engine-side and carburetor-side flanges. · Tolerance Control: We maintain flatness tolerances within 0.05mm to ensure a hermetic seal against the cylinder head, preventing unstable idling caused by air leaks.

Step 7: 100% Leak Testing (Airtightness)

Visual inspection is not enough. Every intake manifold undergoes a Pneumatic Leak Test. We seal the openings and pressurize the internal cavity to detect any porosity defects or cracks. Only parts that maintain pressure are approved, guaranteeing that no "false air" will enter your customer's engine.

Step 8: Final Inspection & Packaging

Our quality team uses Hexagon CMMs to verify the position of mounting holes and the angle of the intake runner. Finally, parts are packed in custom trays to protect the machined sealing surfaces during global shipping.