Alloys: Zamak 3 (ZL3, ZL0400, ZnAI4, alloy 3)

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...
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...
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...
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...
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...