Search Casting Studies
There are 60 studies matching your search criteria.
Antenna Base Housing
Gold Award Winner from China Best Diecasting 2018 This part was an existing part already but brass has been substituted by Zamak5 alloy. It is thin wall, min 0.5mm, and electroplated, so it has high surface requirements for surface roughness, cold shuts, and...
Automotive Shift Level
This shift lever connects the shifter and the gear in ZF automotive gearboxes. This part was originally cast in aluminum but required tapping and other secondary operations in order to meet the close tolerances. Thanks to close collaboration with the customer, the...
Bayonet XT-A
The 3-piece bayonet XT-A is assembled into a circular piece and provided with a cover plate. The part is designed so that it connects with an inlay heatsink, necessary due to the heat generated by the installed LED (60-80°C). The casting challenge is to achieve a...
Bearing Attachment
ln this example, a ball bearing housing which is die cast in alloy Z410 (equivalent to BS 1004B) is attached to a thin continuously electrogalvanized steel sheet pressing. Studs – integral rivets – are cast into the housing. After the steel pressing is located, the...
Busbar for electric fan
As an individual part, the award-winning casting is a very filigree, long and sensitive component. Four individual and very thin conductor strands with dimensions in the millimeter range have to be produced by casting with a cross-section of perhaps just one...
Capstan Retainer
Precision and strength are important design considerations for the minicartridge tape drive, and the capstan retainer is a good example. This part is actually two separate components cast together–a Torx head screw with an integral retainer sleeve. To produce the...
Carrier
Excellence Award Winner from China Best Diecasting 2018 This part has a high level of fine detail and an excellent surface finish after plating. It is difficult to cast and ejection needs to be done carefully to avoid any deformation. The casting process is very...
Case for Wendt & Kühnangel figure
The award-winning cast part “suitcase” is based on the original of a suitcase and represents a decorative part in the series of collectible dolls, made of wood. While suitcases were made of leather many decades ago, there was a separate edge protection...
Caster Housing
This part was cast with Zincopor(R) technology, which resulted in a weight reduction of 25%. With an annual production rate of 235,000 part/year, this represents a 10-ton reduction of zinc alloy.
Central Console
Utilizing zinc alloys to create this part allowed for outstanding control of each step and parameter involved in the full process, from design to final part to achieve, to achieve the perfect design. With die casting, the same surface quality and appearance could be...
Central support for electrical, mechanical & optical parts in detail equipment
This component immediately catches the viewer’s eye because of its size, volume and associated weight. However, these dimensions are necessary for the central support unit in the dental field in order to enable the inclusion of optical, electrical and mechanical...
Central Support Unit
This part is a central support unit for mounting all optical, electrical, and mechanical components for the imaging plate technology in use in dentistry. In medical technology, die cast zinc has been used for many years; however, overall, this area of application is...
Closure ring overhead shower RAINFINITY
In the field of sanitary technology, extremely high demands are placed on the surface appearance, resistance and dimensional stability of the assemblies. A high standard of haptics conveys a high-quality feeling. With the casing of the Rainfinity overhead shower, the...
Computer Rear Cover
Micro-informatics are already an integral part of business and professional life. The will soon be present everywhere, including the home. What role do zinc alloys play? This back cover for a microcomputer illustrates how zinc die castings can simplify design and...
Connector for Radio AM/FM Signal
The part has the following attributes: One of this part’s highlights is its functionality—it allows one single part in Zamak for electrical connection (interface) and mechanical (coding + retention). It also has a connector function, which allows for the transmission...
Cover Plate e-drive
This part is used in a drive system as a special shield to guarantee good air ventilation in addition to perfect cooling of the system. Reasons for choosing zinc alloy include the complex tool design; requirement to cast the part to size; ability to forego using...
Cylinder housing shells and head cap for ABUS-ECO locking cylinders
Groß Druckguss GmbH received this award for the implementation of the housing shells and a head cap for ABUS-ECO locking cylinders. Products in the lock area are characterized by extremely low tolerance ranges and high accuracy of fit and precision. When manufacturing...
Decorative Figure
Honorable Mention, 2018 EU Zinc Die Casting Competition The jury of experts is honoring the expansion of the application areas of zinc die-casting in the arts and crafts with a special prize for Heiligenstädter Reißverschluss GmbH & Co. KG. The zinc die casting...
Dental – Occlusal Bite Holder Block
The medical sector is a highly demanding, niche market. The main benefit of using zinc die casting for this product is the outstanding surface quality achieved.
Die Cast Magnets Lower & Upper Ring
Door closure system INSTINCT by MACO
Smart Home is becoming an increasingly important part of our daily lives. A large number of household appliances, from dishwashers to water purifiers, can now be operated via smartphones. Why not also window and door fittings? With the innovative, fully electronic...
Driving Gears
This is an excellent alternative to engineering plastics, aluminium or milled – sintered steel for the realization of driving gears for toothed belts (electronics) or pinion engagement (building, mechanical, precision hardware). Off-tool net shape thin wall zinc die...
Electronic Connector
The key benefits to this product’s design was a close cooperation between die caster and customer through a clipping system. It utilizes modern assembling technology, and because it does not involve a screw, creep is not a risk.
Electronic Housing
First Place, 2018 EU Zinc Die Casting Competition The housing is cast with extremely thin walls of up to 0.5 millimeters – in the cast thread with an incline of even up to 0.2 millimeters – wall thickness and thus places the highest demands on toolmaking...
Electronics Housing
SINAMICS Control Unit CU305 This casting is a housing for the most demanding industrial electronics. To avoid short circuits, it needs to be free of residual particles. To save costs for post-processing and cleaning steps, a net-shape mold concept was developed....
Escutcheon for overhead shower for Grohe Rainshower series
The award-winning component is a large-scale application of die-cast zinc as a shower head. The large surface area of the cover rosette component of an overhead shower for the GROHE Rainshower series in connection with a galvanic surface treatment places special...
Frame Cover
The high dimensional tolerances possible with zinc die casting permitted precise and reliable seating of 6 bushings, diameter 8 mm/0.31 inches, with a diametral tolerance of ± 0.015 mm without additional machining. The complex shapes achievable in zinc die casting...
Fully casted fitting with thread for compressed air manifold
For this part, zinc was an excellent substitute for brass. Key benefits include: No secondary operation: screw thread directly as cast. Redesigned concept: switching from machined part to casting technology. Split core technology.
Gear Wheel with Shaft
Third Place, 2018 EU Zinc Die Casting Competition This component in the field of office technology is a successful example of composite casting. In this case, zinc is cast with inserts made of stainless steel in order to optimally exploit the properties of both...
Guide and Sliding Door Lever for Monospace
This lever allows the side door to slide in a combined movement with a guiding rail. The guiding is obtained by a bearing attached to the lever end.
Hand Grinding Machine (Georges Renault)
Due to its reliability, zinc allows the mounting of a precision bearing of an air turbine with a bevel gear. It also allows the plastic over coating. Zinc fulfilled the requirements for this design, including strength with precise shapes and thread with repetition at...
Handle for Electrical Cabinet
This zinc alloy part is designed to raise the global quality perception of the final product. The dimensional precision of the process for the fine fitting of different sub assemblies and the long life of the mold and tooling for large production series led the choice...
High Tension Cage
This part is a device component warranting the operators security during intervention on high-tension lines. The reasons behind choosing zinc alloy include the product’s complex tool design, the combination of thin wall casting and rigidity, and the dimensional...
Housing for electro-tool
The drive head of this tool, made out of 2 parts, is cast in ZP5. This casing contains the gear that translates rotating and oscillating movements at very high rpm and frequencies. The part needed to comply with low tolerances for shape and position in both...
Housing for HSD Connector
This HSD connector (HSD = high speed data) is a part of the control units in upper segment cars. The 4-pin connector assures large volume of data transfer as compared to the standard connector with only 1 pin. The required tolerances for this miniature part are...
Housing for KitchenAid Coffee Machine
The 9,5 kg zamak housing of this designer coffee machine is made from 8 zinc pressure die cast parts with weights between 2.2 kg and 75 g. The parts are powder coated. To avoid any bubbles during thermal curing of the paint, the parts are vacuum cast to avoid gas...
Housing for low voltage angle gear drive
This casting is a segment of a multi-piece gearbox for 24/48 volt engines. The cost pressure in the market segment prompted the designers to rethink. A cost-effective production method for manufacturing the individual components that does not require any further...
Inking Stamp for Post Office Franking Machine
This design is an interchangeable stamp on a franking machine. It is coated with ink on the summit of the engraving and stamps the envelope.
LEO Easy Opener
This design opener can open all kind of bottles without any damage and with very little effort. With its innovative patented mechanism, this tool won the Bundespreis 2016 award in Germany. ZP5 was chosen over other materials for its excellent surface finish, strength,...
Light Fittings
Zinc alloy pressure die castings in alloy Z 410 (BS1004B) are used to produce a wide range of light fittings, varying from small individual lights to multi-light chandeliers. A selection of lights is shown here, ranging from small bronze plated lights, gold plated...
Link Between Aluminium Structural Beam
The aluminium structural beam must strongly fostered with water proofing to avoid penetration from the rain or washing water. The geometric position must be sound, and operating live must be assured.
Metal Saw Handle Frame
This product has been created for a top quality, guaranteed-for-life hacksaw. Zinc alloys satisfy the surface coating and the mechanical resistance required for the handle and saw blade guide, with the process economy for a high-quality product on a competitive...
Microprocessor Protection Housing
This part can be created in large production volumes. Assembly is uncomplicated even with complex shapes, competing with pressed steel sheet. Zinc castings’ superior thermal conductivity permits faster and greater heat dissipation provided by thinner radiating fins,...
Modular Base Plate
This part is a modular base plate working in a pneumatic environment. Its function is to transport air between an air distributor and a jack. Modular base plates are made of pressure die cast Zamak 5 (ZA4UIG). The excellent fluidity of zinc alloys provides a surface...
Motorcycle indicator housing BMW R18
For many, the BMW R18 brings back memories of the old days – cruising alone on winding roads, a comfortable ride and good road holding. The vehicle has to have a certain solid and sonorous appearance. With the R18 model, BMW is addressing the buyers of a Harley...
Paper Feeding Guide for Thermic Printer
The anti-magnetic character of the zinc alloys combined with the economic advantages of the production process win over the press formed steel sheet and aluminium profiles.
Reductor
Zinc’s excellent bearing properties at high loads and low speeds permitted it to be used for this part without the use of pressed-in bronze bearings, reducing cost. The required dimensional precision and high required strengths also made zinc die casting the preferred...
Remote car release key, design elements
People carry this cast part with them in many variations: a design element of the car key. The demand for a high-quality look, an appealing, cool feel and the requirements for a robust, largely scratch-resistant surface led to the decision to use zinc as a material....
Remote Control
This high-end remote control’s design has tactile control without any knobs. The zamak surface was cast to a thickness of 0.6mm with less than 0.05mm tolerance on thickness. Piezo elements translate the bending of the surface into electric signals. For casting this...
Shell Part for High Speed Train
Excellence Award Winner from China Best Diecasting 2018 This part has a moderate complexity and an excellent surface finish after plating. Most interesting is the unusual application in high speed trains, which is a segment where lower series volumes can be expected....
Shift lever automatic transmission base lever
The award-winning cast part in the automotive category is a basic lever for the shift lever of an automatic transmission in a car. The gearshift knob is in the constant field of vision of the driver and the vehicle occupants, which places very high demands on the...
Steering Column Housing
Key benefits include: Design and use of a complex tool to avoid multiple secondary operation. Excellent gating control to achieve mechanical tolerances.
Subframe and Carriage
The three parts of this design form a subassembly that measures the thickness of ophthalmic lenses before edging. The frame ensures the palpate lever guidance in the ophthalmic glass machine tool. Then, the glass is machined with the contour note during the palpate...
Support Unit for Drive
This product is a segment drive for imaging plate technology used in dentistry. A complex, modern, and advanced die casting enables precise and optimum shape design that is consistent with the mechanical properties of the die cast zinc alloy. In medical technology,...
Thermostate Valve Housing
Special features of this die cast product include precise dimensions that ensure a perfect fit around the circumference of the housing, making it water-resistant so that the internal components are protected. The tool design allows for uniform filling and casting with...
Traffic Light Housing
Together, these two parts form a protective casing for the internal components of traffic lights. The material properties provide protection against vandalism and have much longer lifetimes than polymer materials. Due to thinner sections, they are also lighter than...
Tuner Housing
Two M4 threads were needed on this zinc die casting in Z410 alloy (equivalent to BS 1004B). Because the holes were at 90° and in different planes, the threading could not be carried out in a single operation. By comparison with two separate threading operations, it...
Window Part
Second Place, 2018 EU Zinc Die Casting Competition This part can be easily installed on site using clips with clamping ribs with a power input of 65 to 75 N. Predetermined breaking points with a defined break at 360 to 460 N allow disassembly if required. To ensure...
X-ray dental technology housing
The award-winning casting is characterized by a completely different zinc die-cast property than strength, filigree and thin walls. Due to its use as a component of an X-ray device, thick-walledness, tightness and also precision are in demand. In addition, the...