Search Casting Studies
There are 59 studies matching your search criteria.
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...
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...
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...
Channel and T-shape
This two-piece holder was developed for a precision scientific instrument. Both castings have detailed features requiring tolerances of +/-0.00025 in. Extrusion could not be used because it could not hold the tolerances, while CNC and wire EDM were not cost effective....
Chassis, Shield and Synthesizer Housing
The Ericsson GE Mobile Communications’ M-PA personal radio incorporates three Zamak 3 die castings: the chassis or circuit board frame, the chassis shield, and the synthesizer housing. These castings combine to provide strength and rigidity demanded for...
Check Valve
Previously, the check valve was assembled from machined aluminium bar stock and brass pipe fittings. A net shape die casting was designed by consolidating the six-piece assembly into a single, net shape component. All holes and seven thread sets, including a male...
Cheque Guide
This single zinc die casting replaced an assembly of stainless steel components. By use of a single casting, rigidity was greatly improved and dimensional precision between critical dimensions was made more reliable. Zinc die casting permitted the required dimensional...
Compact
The wide choice of decorative finishes for zinc alloys – which may be color contrasted with other materials – is a major asset when designing luxury goods. The designer Christian Dior made good use of this capability in creating this attractive compact. 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...
Copper Cable Connectors
Zinc die casting was chosen to produce this new generation of cable connectors. Critical standards that were met include wall strength to assure durability and to withstand bulk processing and proper matching of draft allowances on the internal surfaces for smooth...
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...
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
Different Parts
Cost savings were the initial reason for converting a number of steel stampings into this single zinc die casting. The surface flatness and dimensional precision between features such as fixing studs was greatly improved, this permitted more reliable assembly of...
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.
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....
Ezi – Fill Fuel Dispenser
Its strength, tolerance for accurate detailing, non-corrosive properties compared to aluminium, and production speeds (faster than plastic) made die cast zinc the obvious solution when it came to the manufacture of Unicast’s “Ezi – Fill” fuel dispenser. Manufactured...
Floor Support Pillars
Zinc die cast pillars support two different heights of floor system. The first is a low height (60 – 100mm) system for cables only, and the second is higher (300 – 400mm), used for air ducts under the floor. Zinc die castings are designed for maximum strength....
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 Knob AMG (Mercedes)
This casting part was originally produced in die cast aluminum. It could be produced only with disproportionate effort and high scrap rates. The parting plane in the casting could never reach the surface quality standards because at that position was a vacuum...
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...
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...
Helical Gear
A worm/helical gear set operates the linkage attached to the roof window frame. Originally, the helical gears were machined from brass, reinforced with a formed steel insert and installed with a plastic washer/spacer. The assembled gear’s cost became a factor when...
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 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...
Housing, Plate, and Anvil
Complexity of the shapes allows for the integration of multiple positions. The non-magnetic character of the zinc alloys compared to the plastics work in favor of the design’s long term dimensional stability and reliability.
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.
Lubrication Metering Assembly – Graco, Inc.
The design requirements for the assembly’s 10-in.-long housing called for non-tapered walls in the meter chamber, allowing free rotation of the metering gears and zero draft in the valve area. Previous designs utilized two aluminum castings requiring secondary...
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,...
Microscan Systems – VS 310 Scanner
Designers of an ultra-compact scanner needed to reduce the internal envelope. The optics bracket was one component that was reduced in size but increased in functionality. The goal was to design a single mounting bracket that would accommodate a laser module, a...
Mirror Bracket
The rigidity of this part ensures the quality of retro-vision due to the absorption of the vibrations compared to engineering plastics. Note the (omega) shape for the rigidity of the assembly. Rigidity inside the envelope (volume) and reduced width of the assembly...
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...
Motor Chassis
This chassis for a motor drive unit for an automatic opening roller door was made from several pressed metal parts prior to being designed as a zinc die casting. Die casting in zinc alloy 3 provided numerous benefits: 1.) Additional features such as pockets, the...
Plate
The part is machined on guiding bores and reference faces. It substitutes for the pressed steel plate for several reasons: its high precision realized on machined diameters Ø < 0.02 mm and for the cost efficiency.
Precision Plate ensuring smooth movements of the robot on X and Y axes
This part, which replaced a machined steel part, required precision tolerances for the diameter of the bores and the spacing between them. Zinc casting also provided the required dimensional stability over time and permitted this complex shape to be cast in one piece...
Printer for ‘ATB’ Magnetic Airline Tickets
Zinc alloy pressure die casting has been chosen by the IER company for the four parts that make up the structure of this ticket printer. The specification set by IER required materials and technology that would enable the production of: complex shapes, so that the...
Ratchet Housing
The goal of product designers for the 1/4 in. air ratchet was to lower product manufacturing costs while improving performance and appearance. The original product design specified an axial assembly–a machined steel head attached by a lock nut to a housing handle....
Regulator
The regulator for Turner’s self-igniting torch has a design criteria specifying pressure tightness, strength, cleanliness and metal-chip free, net shape, and cost-effective manufacturing. A screw-machined aluminium or brass regulator was first considered, but both...
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...
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...
Shift paddles on a Porsche steering wheel
A zinc die-casting application in the absolute premium range: This award-winning cast part is tangible on the steering wheel of a Porsche sports car and makes acceleration an experience. The paddles are attached to both sides of the back of the steering wheel and are...
Slave Lock Mechanism
The initial design brief for the slave lock was that it had to have suitable mechanical properties to meet security door standards, have minimum design complexity, and use the most logical material for its purpose. Initially a hybrid construction was considered, using...
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...
Threaded Connector, Moss Joiner
This product is a cylindrical zinc pressure die cast component with an internally die cast thread that functions to tighten the fitting on an outdoor water hose. Zinc alloy no. 3 was chosen because of its stiffness and bright finish that is unaffected by ultraviolet...
Toothed Wheel
This toothed wheel consists of two parts which are assembled with cast-in spigots and bolts in special steel. The parts are made in zinc alloy ZA-27, and apart from trimming, receive no machining or other finishing operations. The part is produced in two sizes, the...
Top and bottom sensor plate – dollar bill changer
A dollar bill changer incorporated top and bottom sensor plates fabricated from welded stamped components. The weldments could not hold tolerances greater than +/- 0.020 in. In an effort to resolve dimensional instability and fit problems, the manufacturer, working...
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...
Transmission Selector Tube – Ford
The original selector tube was designed as a magnesium-steel assembly. It was redesigned as a one-piece ZA-8 alloy die casting. The ZA-8 casting replaced steel without loss of torque strength. Net shape casting produces a complex, multifunctional component. The...