Search Casting Studies
There are 59 studies matching your search criteria.
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...
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...
Bathroom faucet – Delta Faucet
The Delta Faucet’s construction is known as shell technology. It features a die-cast zinc cover, or escutcheon, over a brazed copper and brass assembly. The thin zinc cover is much more uniform than brass; it provides near net shape die casting with tolerances of...
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...
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...
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...
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...
Cup and Cover of Gas Expander
Zinc die cast household gas expanders are often unnoticed but have performed reliably for more than 40 years, even as requirements have become stricter. Zinc castings allow meeting of the pressure tightness specification, which is that the assembly is pressure tight...
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...
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...
DragonFly (TM) camp stove – Mountain Safety Research
The original fuel fitting design was an assembly of three screw-machined components–a brass orifice, an aluminum stop block and lock mount, and a stainless steel hose barb. By redesigning the assembly as a one-piece zinc die casting, a 56 percent cost reduction was...
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...
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.
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....
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...
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...
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...
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 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...
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....
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...
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.
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,...
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...
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...
Mobile Radio Antenna
Zinc die casting was chosen to reduce cost of an antenna base for mobile radio equipment, which was originally a brass screw-machined part. Powder metallurgy was evaluated, but it couldn’t achieve the required undercuts without machining. Zamak 2 alloy was specified...
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...
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.
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...
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...
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...
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....
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.
Strap Adapter, Entry Slide Mount, Belt Sheave
Die casting the three components in ZA-27 alloy offers attractive aesthetics and a near-net shape, which eliminates machining costs. In addition, ZA-27 alloy provides good wear and bearing characteristics.
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...
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...
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...
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...