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There are 138 studies matching your search criteria.

Antenna Base Housing

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Gold Award Winner from China Best Diecasting 2018 This part was an existing part already but brass has been substituted by Zamak5 alloy. It is thin wall, min 0.5mm, and electroplated, so it has high surface requirements for surface roughness, cold shuts, and...
attachm2_photo2_caseID63

Attachment Insert

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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...
ima01

Automotive Shift Level

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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...

Ball Pens

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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...
basepla2_photo2_caseID65

Base Plate and Shaft Support

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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

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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...
ima10

Bayonet XT-A

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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...
Bearing_attatchment

Bearing Attachment

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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...
blackpl2_photo2_caseID68

Blackplate support pad for pin printer

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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

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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

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  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...
capstan2_photo2_caseID70

Capstan Retainer

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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...

Carrier

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Excellence Award Winner from China Best Diecasting 2018 This part has a high level of fine detail and an excellent surface finish after plating. It is difficult to cast and ejection needs to be done carefully to avoid any deformation. The casting process is very...

Case for Wendt & Kühnangel figure

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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...
ima06

Caster Housing

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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.  
ima04

Central Console

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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...
ima08

Central Support Unit

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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...
channel2_photo2_caseID71

Channel and T-shape

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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....
chassis2_photo2_caseID72

Chassis, Shield and Synthesizer Housing

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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...
checkva2_photo2_caseID73

Check Valve

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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...
chequeg2_photo2_caseID74

Cheque Guide

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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...
cigaret2_photo2_caseID75

Cigarette Lighter Case

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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

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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...
compact2_photo2_caseID76

Compact

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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...
ima15

Connector for Radio AM/FM Signal

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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...
connect2_photo2_caseID79

Connector Housing – Berg Electronics MICROPAX ™ connectors

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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...
control2_photo2_caseID80

Control Boxes

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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...
cableconnect2_photo2_caseID128

Copper Cable Connectors

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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

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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...
ima01

Cover Plate e-drive

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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...
cupcove2_photo2_caseID130

Cup and Cover of Gas Expander

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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...

Decorative Figure

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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...
ima13

Dental – Occlusal Bite Holder Block

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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.
differe2_photo2_caseID112

Different Parts

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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...
doorbra2_photo2_caseID166

Door Brake

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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

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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...
valvespace2_photo2_caseID167

Double-Diaphragm Pump – Warren Rupp

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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...
fitting2_photo2_caseID168

DragonFly (TM) camp stove – Mountain Safety Research

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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...
driving2_photo2_caseID170

Driving Gears

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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...
ima14

Electronic Connector

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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.

Electronic Housing

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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...
ima11

Electronics Housing

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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....
doorcl2_photo2_caseID172

End Cap for a Pneumatic Door Closer

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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

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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...
ezifill2_photo2_caseID173

Ezi – Fill Fuel Dispenser

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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

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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

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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...
4a2_photo2_caseID135

Foot Switch – Control International

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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...
frameco2_photo2_caseID113

Frame Cover

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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...
frameho2_photo2_caseID114

Frame Housing and Five Additional Mechanical Components

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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...
frontpl2_photo2_caseID137

Front Plates

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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...
gearcac2_photo2_caseID176

Gear Case (III)

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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...
gearho2_photo2_caseID138

Gear Housing

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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...
ima07

Gear Knob AMG (Mercedes)

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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...
gearrac2_photo2_caseID115

Gear Rack and Housing

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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...

Gear Wheel with Shaft

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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...
gridmod2_photo2_caseID116

Grid Module

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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...
handgri2_photo2_caseID82

Hand Grinding Machine (Georges Renault)

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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...
handlea2_photo2_caseID83

Handle and Backplate

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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.
handlef2_photo2_caseID85

Handle for Electrical Cabinet

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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...
heatsink2_photo2_caseID86

Heat Sink

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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...
helical2_photo2_caseID87

Helical Gear

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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...
ima07

High Tension Cage

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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...
housinf2_photo2_caseID89

Housing & Frame

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The elements of this equipment (TYCAS) were created to detect the positions of approaching aircraft according to new security norms of the IATA. The process proved to be more economical compared to traditional machining despite limited series and to pressure die cast...
housing2_photo2_caseID91

Housing Cover and Thumbturn – Medeco STEELGUARD(tm) Lock

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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...
ima09

Housing for electro-tool

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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...
ima05

Housing for HSD Connector

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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...
ima03

Housing for KitchenAid Coffee Machine

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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

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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...
housinp2_photo2_caseID92

Housing, Plate, and Anvil

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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.
housinl2_photo2_caseID93

Housings for Laser Photocoagulator

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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...
jewelle2_photo2_caseID95

Jeweller’s perfume

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The famous Parisian jeweler Boucheron has created a perfume with a particularly outstanding design of bottle – an enlargement of a ring. The blue cap symbolizes a cut stone, while the bottle itself is supported in a fine gold-plated ring. This part – die cast in zinc...

Keyboard Dock

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Gold Award Winner from China Best Diecasting 2018 Due to its size, this part is cast on a 800T cold chamber machine. The part is used to dock or connect a keyboard and has 2 handles for manual manipulation. The weight is needed to give a robust and stable appearance...
lawnedg2_photo2_caseID96

Lawn Edge Trimmer

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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...
leadscr2_photo2_caseID97

Lead Screw

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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...
ima08

LEO Easy Opener

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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,...
linkalu2_photo2_caseID100

Link Between Aluminium Structural Beam

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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.
lockabl2_photo2_caseID101

Lockable Door Knob – Model 930

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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...
lockin2_photo2_caseID102

Locking Hub

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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...
6b2_photo2_caseID104

Lubrication Metering Assembly – Graco, Inc.

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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...
metalsa2_photo2_caseID105

Metal Saw Handle Frame

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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...
micropr2_photo2_caseID106

Microprocessor Protection Housing

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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,...
lasermt2_photo2_caseID107

Microscan Systems – VS 310 Scanner

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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...
microwa2_photo2_caseID177

Microwave Guides (5 configurations)

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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...
mirrorb2_photo2_caseID117

Mirror Bracket

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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...
gearbox2_photo2_caseID129

Miter Gear Box – Hunter Douglas Venetian Blind

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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

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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...
modular2_photo2_caseID179

Modular Base Plate

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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...
motorch2_photo2_caseID118

Motor Chassis

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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...

Motorcycle indicator housing BMW R18

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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...
panelnu2_photo2_caseID108

Panel Nut – Ignition Switch

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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...
paperfe2_photo2_caseID109

Paper Feeding Guide for Thermic Printer

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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.
hub2_photo2_caseID110 (1)

Peerless Pull-Out Faucet – Delta

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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...
perfume2_photo2_caseID111

Perfume Vaporizer for Hand Bags

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This set of six parts, four of which are made of Zamak, makes up a rechargeable perfume vaporizer. There are several notable characteristics of the final product that illustrate the versatility of the zinc alloy pressure die casting process: complexity of the assembly...

Planter Handler

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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...
plate2_photo2_caseID140

Plate

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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.  
printer2_photo2_caseID120

Printer for ‘ATB’ Magnetic Airline Tickets

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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...
Pg1asq2_photo2_caseID181

Q-LOK cleat fastening system – MacNeill Engineering/Worldwide

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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...
quickclamp2_photo2_caseID182

Quickclamp Air Prep System – IMI Norgren

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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...
ratchet2_photo2_caseID144

Ratchet Housing

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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....
reducto2_photo2_caseID147

Reductor

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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...
regula2_photo2_caseID184

Regulator

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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 car release key, design elements

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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....
ima04

Remote Control

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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...
wheelhse2_photo2_caseID149

Seat Belt and Wheelchair Restraint Housing

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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...

Sensor Plate and Sensor Activation Button

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This part has an excellent surface mirror finish after plating. The feeding is done with a center gate to avoid too long metal flow distances which negatively affect surface quality. This part was an existing part already, but ABS has been substituted by Zamak3 alloy...

Shell Part for High Speed Train

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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....

Shift lever automatic transmission base lever

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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...
slavelo2_photo2_caseID185

Slave Lock Mechanism

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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...
spotlam2_photo2_caseID151

Spot Lamp Body

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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...
ima02

Steering Column Housing

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Key benefits include: Design and use of a complex tool to avoid multiple secondary operation.  Excellent gating control to achieve mechanical tolerances.
strapad2_photo2_caseID186

Strap Adapter, Entry Slide Mount, Belt Sheave

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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.
structu2_photo2_caseID152

Structural Components

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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...
ima06

Subframe and Carriage

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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...
ima09

Support Unit for Drive

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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,...
ima05

Thermostate Valve Housing

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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...
threade2_photo2_caseID187

Threaded Connector, Moss Joiner

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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...
toothed2_photo2_caseID154

Toothed Wheel

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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...
topandb2_photo2_caseID155

Top and bottom sensor plate – dollar bill changer

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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...
tracing2_photo2_caseID125

Tracing Machine

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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...
ima11

Traffic Light Housing

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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...
transmi2_photo2_caseID126

Transmission Selector Tube – Ford

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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...
tunerho2_photo2_caseID157

Tuner Housing

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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

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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

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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...
wavegui2_photo2_caseID190

Waveguide Horn

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The Whistler Spectrum 3SE waveguide horn is a complex Zamak 3 die casting providing detail, net shape, and thin wall construction. The current horn replaces three separate pieces utilized in earlier models. One component now performs four distinct functions: a horn...

Window Part

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Second Place, 2018 EU Zinc Die Casting Competition This part can be easily installed on site using clips with clamping ribs with a power input of 65 to 75 N. Predetermined breaking points with a defined break at 360 to 460 N allow disassembly if required. To ensure...
wirejoi2_photo2_caseID191

Wire Jointing Device

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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,...

X-ray dental technology housing

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  The award-winning casting is characterized by a completely different zinc die-cast property than strength, filigree and thin walls. Due to its use as a component of an X-ray device, thick-walledness, tightness and also precision are in demand. In addition, the...
xraytan2_photo2_caseID161 (1)

X-ray tank+lock+guide Tube Assembly

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The X-ray tank + lock + guide assembly consists of a very high frequency generator for dental radiology. The parts in this assembly are made of pressure die cast Zamak 5 (ZA4IUG), an alloy which offers the following functions for this application: mechanical strength,...
platen3_photo3_caseID163

Z Series Printers – Zebra Technologies

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The platen housing design incorporates three previous parts. In order to function properly, the material must be rigid and strong. The housing is cast with four elongated slots, four deep slots, and seven cored holes, maximizing the need for structural support. In...