Die Casting T1 Sample Approval Checklist

T1 is the first sample produced from the new tool. Its purpose is to confirm that the tool, the process concept and the part definition work together before volume production is released.

A T1 sample is not a production release by itself. It is the evidence used to decide what changes are needed and whether the project can move to the next stage.

• T1 is the first sample from the new tool
• It validates tooling and process concept
• It is not an automatic production release
• It drives the change list

Review the dimensions that the drawing identifies as critical, plus the features that affect assembly, sealing and function. Confirm the datum strategy used for inspection matches the drawing.

Material records, hardness or composition information and process notes should be available with the sample. These records form the basis of the approval decision.

• Inspect critical and functional dimensions
• Confirm the inspection datum
• Collect material records
• Compare against the controlled drawing revision

Cosmetic requirements should be reviewed under the agreed lighting and against an approved sample or limit sample. Flash, flow marks, cold shuts and porosity visible on the surface need a clear acceptance decision.

Functional features such as sealing surfaces, threads, bores and mounting interfaces should be checked in the same review, together with any leak or pressure test required by the project.

• Review under agreed lighting
• Approve or reject cosmetic zones
• Check sealing, threads and bores
• Run the agreed functional tests

The approval decision should list every deviation with a disposition: accept, rework, redesign or retest. Changes to the drawing or tool should be recorded against the revision.

Once the sample is approved, the tool state and process settings become the production baseline. Any later change to tool or process should trigger a controlled review.

• Record every deviation with a disposition
• Link changes to the drawing revision
• Lock the approved tool and process state
• Review later changes through change control