Search Casting Studies
There are 27 studies matching your search criteria.
Capstan Retainer
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...
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...
Check Valve
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...
Cheque Guide
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...
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...
Corner Stake – Security Door
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...
Cup and Cover of Gas Expander
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...
Different Parts
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...
Electrical Auxiliary Switch Cam
A starter for large horse-power motors incorporated a fabricated sheet-metal cam bolted to a bracket and welded to a shaft. To simplify manufacturing and reduce cost, the cam design was changed to a single-piece ZA-12, graphite permanent mold casting. Additionally,...
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.
Foot Pedal Level
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...
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...
Frame Housing and Five Additional Mechanical Components
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...
Fully casted fitting with thread for compressed air manifold
For this part, zinc was an excellent substitute for brass. Key benefits include: No secondary operation: screw thread directly as cast. Redesigned concept: switching from machined part to casting technology. Split core technology.
Gear Case (III)
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...
Handle and Backplate
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.
Housing and Base Plate
Originally, the housing and base plate frame were sand cast aluminium and finish machined. Machining and assembly time took 3.5 hours per unit. During a redesign, the company set about to reduce costs without sacrificing quality or performance. This led to graphite...
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, Plate, and Anvil
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.
Lead Screw
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...
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...
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....
Steering Column Housing
Key benefits include: Design and use of a complex tool to avoid multiple secondary operation. Excellent gating control to achieve mechanical tolerances.
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,...
Transmission Selector Tube – Ford
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...
Two-Piece Housing
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...