Search Casting Studies
There are 30 studies matching your search criteria.
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...
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...
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...
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....
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...
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...
Gear Wheel with Shaft
Third Place, 2018 EU Zinc Die Casting Competition This component in the field of office technology is a successful example of composite casting. In this case, zinc is cast with inserts made of stainless steel in order to optimally exploit the properties of both...
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.
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...
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...
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 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...
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...
Low-Speed, High-Load Bearings
The Champion Series IV grader incorporates ZA-12 alloy low-speed, high load bearing to improve operation performance. This Front Axle Bearing application acts as a replacement for the grader’s front axle needle bearings. The original needle bearings performed well...
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...
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,...
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...
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...
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.
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...
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....
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...
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...
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...
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...