Casting Study: Connector Housing – Berg Electronics MICROPAX ™ connectors

Major Selection Criteria: Dimensional Precision, Electrical Properties, Good Finish
Alloy: Zamak 3 (ZL3, ZL0400, ZnAI4, alloy 3)
Application Field: Electrical/Electronics
Application Size: Super Small
Surface Finish: Plated
Casting Technique: Pressure Die Casting
Source: Cast Products Inc., Norridge, IL

connect2_photo2_caseID79MICROPAX 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 projecting blades having 0.035 in. walls tapering to 0.028 in. Additional criteria include mounting holes of .040 in. diameter and lead-in Y-grooves with a tolerance of +0.000 in./-0.001 in. Zamak alloy offers four distinct advantages over aluminium for this application: thinner-wall construction; ease of plating; longer die life; and lower energy costs.