Search Casting Studies
There are 90 studies matching your search criteria.
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...
Approach Post Foot
The casting design was engineered to provide the surface finish on the decorative areas while providing adequate strength and reducing cost. The existing weldment design was problematic because of the metal fill direction through the cavity. Working with the customer,...
Attachment Insert
This high performance self-drilling insert for plaster board (partition, lining, ceiling) is delivered with a self-tapping screw, forming two parts (cap and toggle) produced in a single casting operation. The parts are connected by four 0.9 mm diameter pins, which...
Automatic force wedge
The automatic force wedge shown is part of the additional locking devices of the mechanical-automatic door lock “Roto Safe A | Tandeo”. With this door lock, front doors can be locked automatically without using a key. In conjunction with an additional drive unit, the...
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...
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...
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...
Blackplate support pad for pin printer
Modern printers require a pin support which must be cast pore free, non-deformable, and of precise dimensions. Because of the large numbers of units produced, the life of the die is a determining factor. From the client’s point of view, the sound dampening qualities...
Bolt Guide – Remington Powerhammer
A value analysis on the Remington Powerhammer targeted the bolt guide for cost reduction. The bolt guide was originally designed as a screw machined steel component. After prototyping and testing, engineers decided that die casting and ZA-8 provide the design...
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...
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...
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...
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...
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 Brake
Automatic closing mechanisms for swing doors have to be adjustable and brake the movement of the door. The mechanism must be strong, resistant, reliable, and compact enough to be housed in a casing. Pressure injected zinc alloy casings offer undeniable advantages,...
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...
Double-Diaphragm Pump – Warren Rupp
For this design, a series of machined stainless steel air valve spacers were replaced with zinc die castings. Because of the spacer’s large flow areas, engineered plastics do not have the required strength to maintain shape and rigidity. Die cast ZA-8 was chosen for...
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....
Electrical Auxiliary Switch Cam
A starter for large horse-power motors incorporated a fabricated sheet-metal cam bolted to a bracket and welded to a shaft. To simplify manufacturing and reduce cost, the cam design was changed to a single-piece ZA-12, graphite permanent mold casting. Additionally,...
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.
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....
Foot Pedal Level
The lever was originally designed as a steel sand casting with machining operations to size the shaft, pivot hubs, and cable connection holes. The final operation was a zinc plating. After a value analysis of an all-metal foot pedal control system, the materials...
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...
Frame Housing and Five Additional Mechanical Components
Key material requirements for the office bundling machine are hardness and strength, the ability to hold good tolerances, and lubricity. ZA-27 was selected as the die casting material because of its hardness, strength, dimensional stability, and natural lubricity. By...
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 Case (III)
Wen Products designed a new line of jig and pruning saws which required a rugged gear drive. This drive utilizes a complex case design which mounts to the motor, houses the drive gears, and guides the reciprocating blade. The case also provides the required spacing...
Gear Housing
Engineers decreased time-to-market by utilizing existing gear housing tooling to develop a higher load winch. Superwinch’s 1,500-lb. unit incorporated two 380 Aluminium die cast housings which functioned as rotating and stationary ring gears. By substituting ZA-27...
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...
Gear Rack and Housing
One of the first opportunities to test ACuZinc 5 was in Delphi Interior and Lighting System’s newly-designed heliscrew horizontal actuator for power seats. The die castings replace a powder-metal gear rack and plastic gear housing design. Seat adjustment is comparable...
Grid Module
Mosaic mimic panels form a display system that provides an overall picture of complex operations and gives technicians the ability to monitor and control events. The system’s main advantage is its modular design, providing flexibility for easy modification and...
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.
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....
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...
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 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 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...
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.
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...
Lead Screw
Field problems with a gear-driven lead screw assembly prompted the company’s engineers to re-evaluate the design. The gear drive comprised a steel screw-machined shaft and a plastic gear. Assembly required the plastic gear to be pressed onto the shaft. Failures...
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,...
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...
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...
Miter Gear Box – Hunter Douglas Venetian Blind
A four-piece miter gear assembly utilized zinc die casting for strength and precision. Both pinion gear shafts and housing halves are die cast net-shape, achieving full functionality without a cost penalty compared to alternative designs (thermoplastic housing/gears...
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...
Panel Nut – Ignition Switch
Ignition switch corrosion was the source of customer frustration and concern. Standard panel nuts, like the ones used to secure the ignition switch to the riding mower control panel, are made of stamped steel. The die cast company’s technical staff proposed changing...
Planter Handler
The planter handle is used to adjust spring force to a pair of closing wheels. It is important for the handle to be durable, easily accessible, and very comfortable to grip. To accent product appearance, designers chose a die cast over a welded fabrication. Die cast...
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...
Q-LOK cleat fastening system – MacNeill Engineering/Worldwide
Initially, the Q-LOK design was all plastic for low-impact sports. However, for high-impact sports such as soccer and football, the added strength of zinc alloy was necessary to meet impact requirements. Die cast zinc provides the receptacles with superior corrosion...
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...
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....
Reduction Gear
The seats in luxury cars are moved forwards and backwards by motorized reduction gears which must be solid, reliable, accurate, and mechanically strong. Zinc alloys satisfy these requirements and offer the added benefit of noise reduction due to their density.
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...
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...
Roof-Bolt Wedge Anchors
When the AKZO Salt Company had problems getting roof-bolt wedge anchors from its malleable-iron foundry supplier, it opened the door for zinc alloy. Mine management set out to find an alternative source for these vital parts, but they were unable to find another...
Seat Belt and Wheelchair Restraint Housing
Originally, safety belt retractor housings were plastic injection molded. The plastic housings were easily damaged and caused retraction to malfunction. To meet performance standards, zinc die casting was selected to produce the housing and meet performance and...
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...
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,...
The key safe
The SUDHAUS key safe is a secure storage place for keys and other valuables. The dimensions were chosen so that bunches of keys and credit card formats can be stored. Areas of application include contactless key handover for holiday homes, rental car collection/return...
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...
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...
Tracing Machine
Océ Graphics – one of the world’s leading manufacturers of tracing machines – uses zinc alloy die castings in each of the seven machines in its range. Zinc alloy castings form part of the structure of the machines, through the two side plates and two grips in the...
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...
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...
Two-Piece Housing
When Black & Decker decided to introduce a new manual staple gun, designers and engineers started with a clean slate. Their goal was to integrate efficiency, simplicity, and ergonomics into the new tool. The result is a radical design that moves the handle pivot...
Two-Piece Punch Body
For three generations, B-V has been producing heavy-duty, specialty hand punches from two sand-cast malleable iron halves. Sand casting inaccuracies required sorting and extensive fitting to locate matching halves. Thickness variations up to 0.025 in. were...
Vise Components
Eight separate ZA-12 alloy castings are utilized in the TUCKER woodworking vise. Castings form the pivot block, front jaw, rear jaw, quick-release nut, yoke, stanchion, mounting plate, and keeper plate. Based on the shapes needed to form the vise, casting easily...
Wire Jointing Device
Estate Wire Ltd. established a massive potential market for a simple but effective wire jointing device. A specialized design consultancy service – Cheshire Engineering Ltd. – was commissioned to investigate the possibilities. After rejecting a number of alternatives,...