Search Casting Studies
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Air Extractor Cover
In their original version, these parts were produced in glass fiber reinforced resin, 3-4.5 mm thick and containing two brass inserts to fix them to the car body. These components are painted on the body to match the rest of the car. Problems encountered during...
Antenna LNB/Feedhorn Assembly
Feedhorn incorporates six graphite permanent mold castings, including the end cap, housing (which holds the circuit boards), feedhorn, cover (used for shielding), and two mounting probes. ZA-12 alloy provides the components with the necessary strength to withstand the...
Ball Pens
This range of pens – the “Golf” series – is characterized by clean lines and an antique appearance produced by symbols in fine relief on the surface. The thin castings – wall thickness of 0.7 mm – have enabled the total weight to be kept low, while the technology of...
Base Plate and Shaft Support
While competitive versions rely on plastic, the Morse Controls high-end pleasure boat mechanical steering control utilises ZA-8 alloy die casting for the Command 290 base plate and shaft support. ZA-8 alloy was chosen for two reasons: superior mechanical properties...
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...
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 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...
Cigarette Lighter Case
This series of cigarette lighters consists of a range of different models, each of which appeals to the individual taste of the user. The most prestigious models are given appropriate names: Golf, Nantes, Macito, Connubio, Mississippi, and Gigolò. The thickness of the...
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...
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 Boxes
The control boxes for Minn Kota electric motors went through several design phases before settling on zinc die casting as the material/process of choice. The boxes were originally sand cast aluminium and later die cast aluminium. Short tool life prompted engineers to...
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...
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...
Corner Stake – Security Door
The zinc pressure die cast corner stake, fastened with pop rivets, fits tightly into the Galvabond roll form section of the door. It has to compete with plastic molded, aluminium extruded, and aluminium pressed parts’ this is because of the many properties of the zinc...
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
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....
End Cap for a Pneumatic Door Closer
Alloy 3 was chosen as the end cap material because of the ease with which it is processed. Both material and tooling cost are minimized, and the product can be made with existing expertise and plant equipment. Alloy 3 castings can be produced with high dimensional...
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...
Foot Switch – Control International
Over time, the costs associated with machining the cast-iron switch cover eroded manufacturing margins. The decision was then made to zinc die cast the cover. Zinc had the density and weight Control International specified, and it provided better fit, quality, and...
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...
Hammer Cap
Operating at pressures ranging from 50 to 125 psi, the Danair Aerosmith hammer delivers up to 1,000 hammer blows per minute. During the early production phase finish machining exposed casting porosity and the cast iron air grille vents frequently broke during service....
Handle and Backplate
Pictured is one model of a range of decorative door handles. Zinc is used for the design because of its ability to easily take a plated finish and because it can be cast to accurate dimensions.
Handle and Lock Assembly
In both residential and commercial construction projects, architects are frequently asked to design large windows and sliding glass doors. Sliding doors must be easy and comfortable to operate from either inside or outside, and it must be possible to lock them. Zinc...
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 Cover and Thumbturn – Medeco STEELGUARD(tm) Lock
To meet market requirements, Medeco wanted to develop a new high security lock priced just below its top-of-the-line dropbolt lock. The high-end lock model is all brass. The housing cover is investment cast, and the thumbturn is a machined extrusion. As other...
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...
Housings for Laser Photocoagulator
The laser photocoagulator is used in the treatment of eye disease, particularly the treatment of broken blood vessels within the eye. Such a sensitive – and expensive – high-tech tool needs a housing which, besides its functional qualities of soundness, strength, and...
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.
Lawn Edge Trimmer
The innovative Qualcast Lawn Edge Trimmer, the design of which is patented, is entirely based on zinc castings, which are used for both drive train and housings. The trimmer is attached to the standard Concorde mower by replacing the existing belt drive cover with a...
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.
Lockable Door Knob – Model 930
The main feature of this lock design is that the handle is cast with a cylindrical shaped wall, but it is then post formed to a spherical shape. If the Alloy 3 used for this casting did not have high ductility, the final shape could not be achieved and the pressure...
Locking Hub
Warner Gear’s 4WD locking hub takes advantage of ZA-8’s net shape castability, creep resistance, and excellent finishing characteristics to provide a highly functional and aesthetic cover. ZA-8 alloy was chosen because it handles temperatures close to 200 degrees F, a...
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...
Microwave Guides (5 configurations)
Wave guides are built to exacting specifications in dimensional accuracy, straightness, and flatness. Hot chamber die casting enables critical cavity sections to be cast with little or no draft; very difficult in aluminium cold chamber die casting. Flatness tolerance...
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...
Peerless Pull-Out Faucet – Delta
Initially, the hub–two intersecting cylinders–was a brazed assembly. Cylinders were screw machined from solid brass. Operations included turning, drilling, internal milling, cut-off, and rolling of one cylinder end to accept a plastic transition piece. The redesigned...
Quickclamp Air Prep System – IMI Norgren
A newly designed air preparation system utilizes zinc die casting for the major components of the Quickclamp(TM) assembly (as well as the bodies, bowls, and accessory parts of the filters, regulators and lubricators). Die cast zinc provides greater strength than...
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...
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...
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...
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...
Structural Components
The KitchenAid mixer utilizes zinc die castings for all of its structural components–the 4-1/2-quart pedestal model incorporates seven zinc castings, and the 5-quart bowl support model incorporates eight zinc castings. Zinc castings provide a number of design...
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,...
Tableware
Zinc die casting can help create a gracious atmosphere for entertaining when used in the form of attractive tableware, where good shape and meticulous finish are both important. The wide range of excellent surface finishes rely on both the experience of platers and...
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...
Trim Frame
The instrument incorporates two frames, one for the front panel and another in the rear. Originally the frames were designed as welded aluminium extrusions. In search of alternative methods, the manufacturer looked to zinc graphite permanent mould casting with its low...