Search Casting Studies
There are 28 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...
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...
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...
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...
Connector Housing – Berg Electronics MICROPAX ™ connectors
MICROPAX connectors have very demanding specifications which are met by zinc die casting, including: Complex design requirements to accommodate a variety of connectors, ranging from 40 to 200 connecting pins; flatness across the mounting plane within +/- 0.005 in, and...
Control Handles and Mounting Box
ZA-12 graphite permanent mold castings are used for the gunner’s control handles and mounting box because the process is an economical low-volume casting method. ZA-12 also provides the handles with the density to simulate steel. Graphite permanent mold casting is...
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...
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...
Drive Beck
The drive deck for Cherokee’s 5-1/4 in. WORM optical drive utilizes a ZA-12 graphite permanent mold casting. From the start, graphite permanent mold was the process of choice because of its economical tooling cost, good dimensional control, and low-volume economies....
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....
Front Plates
The Accent range of wiring accessories launched by MK Electric last year makes extensive use of zinc pressure die casting and the highest standards in both painted and plated finishes to achieve a combination of slim-line good looks and high-quality feel. A mix and...
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...
Heat Sink
Zinc die casting offers numerous advantages over aluminum extrusion in a number of heat sink applications. Die cast zinc heat sinks offer one-piece construction, increased design flexibility, and lower cost. One of the biggest advantages is that heat-dissipating fins...
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 & Frame
The elements of this equipment (TYCAS) were created to detect the positions of approaching aircraft according to new security norms of the IATA. The process proved to be more economical compared to traditional machining despite limited series and to pressure die cast...
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 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...
Housing MX bottom shell R2S3
With this modular concept, various pluggable, cast housing components can be installed in the system as required. The concept implements a new, complex and resource-saving control cabinet technology. The combination of system function modules and a housing base...
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,...
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...
Shielded connector for electrical engineering
Plug connections in electrical engineering are highly complex components that have to be delicate yet stable due to the space available. Added to this is the shielding function of different conductors in the housing. The award-winning shield housing is a true...
Spot Lamp Body
By using hot chamber pressure die casting for this product, Fos Nova SpA obtained excellent results both functionally and aesthetically while saving on production costs. Of special interest in this part is that the casting was fed through the central opening, which...
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...