Die Casting Solution Profiles

Household appliances - material waste is eliminated and high strength, creep resistant zinc alloy meets operating specifications.

Die casting a shaft configuration used in a clothes dryer increases productivity and eliminates the waste of a screw machining operation. Finite Element Analysis (FEA) was used to prove the viability of a staking operation between the shaft and its mating part. ZAMAK 3 and 5 zinc alloys creeped in the shaft's operating environment, so FisherCast Global recommended ACuZinc. With the highest structural strength and creep resistance of all zinc alloys, ACuZinc meets the required specifications. A tool insert reduces tooling cost for a second shaft configuration.

Flash-free, net shape components with tight tolerances have:
  • overall diameter held within 0.025 mm (.001")
  • dimensional tolerances of 0.05 mm (.002")
Industrial controls - die casting produces high standard gear forms and unique internal shape without machining.

A manual override shaft used in heating system damper controls is die cast in ZAMAK 2 alloy. Slides in the tool produce a blind hole at each end of the component as well as the gear produced to an AGMA Quality Class 6 specification. Dimensional tolerances are typically 0.1 mm (.004").
  • unique internal shape is formed without machining
  • flash-free net shape - no secondary finishing
  • part-to-part consistency.

Automotive - circular runout critical for performance/ part-to-part consistency.

To ensure uniform fill of the tooth form in a front end plate of a windshield wiper motor, FisherCast Global's unique center (through-hole) gating process injects molten alloy from the inside to the outer most edges of the component. Three slides produce the three blind holes which are perpendicular to the tooth form.

  • Critical to the front end plate's performance is the circular runout of the tooth form which is held to within 0.08 mm (.003") relative to its datum surfaces
  • Dimensional tolerances are typically 0.13 mm (.005").

Industrial controls - unique gating technique ensures quality of complex internal splines/no secondary operations.

A hub used in as a control mechanism for gas valves requires four side cores in the die cast tool to produce the undercuts. FisherCast Global's unique center gating provides uniform alloy distribution to form the internal splines and castellated end.

  • Circular runout of the outside diameters is held within 0.076 mm (.003").
  • Complex geometry is cast net shape - no secondary operations are needed.

Hardware - high strength ACuZinc alloy meets performance specifications.

The ZAMAK range of alloys could not meet the strength performance requirements of a rack used in a door lock assembly. With long experience in die casting ACuZinc, FisherCast Global recommended the use of this higher copper content alloy which provides enhanced tensile strength. The tolerances held on the tooth forms were critical.

  • The height and the depth of the tooth forms are held within 0.025 mm (.001") relative to the pitch line.
  • The tooth crest radii are held within 0.051 mm (.002")

Hand and edge tools - die casting improves quality/reduces manufacturing costs.

Costs are reduced and quality improved by casting a shift cap for a racheting socket wrench. A slide is used to keep the head of the cap free of parting line witness marks.

  • Part-to-part consistency over long production runs
  • Net shape - no secondary operations
  • Inserts reduce the cost of casting different size shift caps

Electronics / Telecom - Complex geometry is cast flash-free, zinc alloy provides EMI/RFI shielding properties.

The complex geometry of an electronic connector for audio systems needed a very complex tool configuration to produce features on five sides of the component. Normally this would be accomplished with a single cavity tool, which increases production cost. FisherCast Global's tooling technology allows all features to be cast in a two cavity tool with cores pulled on five of the components six planes.

  • Cores forming the holes seal tightly, producing a flash-free component
  • Zinc alloy's inherent EMI/RFI shielding properties reduce manufacturing cost
  • Dimensional tolerances typically 0.05 mm (.002").

Stronger Gears at Lower Cost

Die casting is well known for reducing manufacturing costs in external, internal, face, helical, spur, and worm gears -- casting them to AGMA 6 to 8 specification. Most tooth forms can be cast, including teeth with helix angles as great 20. Up to 50 external threads/inch are cast flash-free to Class 2A tolerance without cleaning or chasing, as are multi-start threads.

Gating through the center bore of this horizontal gear drive ensures uniform alloy distribution for consistent fill of the thread and gear tooth forms. The walls of the center hole are held parallel within +/-0.0005 in. The drive gear, used in an automobile seat, is cast ready to use with no finishing or deburring operations required.

The potential for piece price reduction is the usual motivation for high-volume die casting. Economies of scale start at 50,000 pieces annually. Numerous factors can affect production economics. These include component complexity, alloy properties, die-casting technology used, precision of the die-cast tool, and cycle rate. One reason die casting can be thrifty is that a single cast part often replaces multiple components. And it is frequently possible to incorporate features in the casting that eliminate secondary milling, boring, reaming, and grinding operations. Convert with FisherCast Global and Save up to 70%!

Our leading-edge technology can deliver better components at lower cost. You could save up to 70% by switching to FisherCast Global's unique die casting process from your current small component production method. For example, if you are using the powdered metal process, you could be paying for more strength than you really need. Or, if you are using the screw machine process, you may be paying for wasted material.

Switching to FisherCast Global gives you three immediate benefits:

  • Multiple features and complex geometries
  • Superior part-to-part consistency
  • Elimination of secondary operations

High precision, flash-free tooling, combined with our proprietary die casting systems, enables FisherCast Global to produce your components to the tightest tolerances over long production runs, and the net shape components are ready-to-use with no secondary trimming or deburring required.

In fact, cross-holes and other complex features can be made as part of the die casting process. You can even die cast logos, part numbers and other coding information. ACuZinc and other higher copper content zinc alloys can also be used for applications that require special mechanical properties.

So you get more complex shapes with tighter tolerances and better part-to-part consistency for less than you are paying now - often a lot less. Our experienced Application Engineers will work with you to deliver components with the characteristics and performance you require.