Search Casting Studies
There are 18 studies matching your search criteria.
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...
Baugruppe Fußtüröffner
das Gussteil ist Teil einer Baugruppe für einen mechanischen Türöffner, der mit dem Fuß bedient wird. Berührungslose Türöffnung ist beispielsweise in Krankenhäusern oder öffentlichen Sanitäranlagen unter hygienischen Aspekten ein Gewinn. Der Einbau erfolgt in...
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...
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...
Connector for Radio AM/FM Signal
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...
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...
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.
Elektronische Lenkungsverrie gelung: Anbindung und Sockel
Die Baugruppe besteht aus einer Anbindung und einem Sockel als Hauptelemente einer elektronischen Lenkungsverriegelung. Dabei handelt es sich um Sicherheitsteile aus dem Automotivebereich, die durch ihre Materialeigenschaften und komplexen Konturen Funktionen...
End Cap for a Pneumatic Door Closer
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...
Heat Sink
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...
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...
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...
Microscan Systems – VS 310 Scanner
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...
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...
Peerless Pull-Out Faucet – Delta
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...
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,...