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In the 2023/24 Winter edition of Inside CWM, take a career journey with CWM’s very own Judy Rhodes. Learn about what goes into CWM’s twice-weekly safety audits. Help us congratulate two CWM Employees who got married! Recognize the hard work of the 2023 service award winners. Look back at the CWM Christmas Luncheon – the first once since COVID. Celebrate CWM’s 2023 Outstanding Performers of the Months/Year. Take a look at the story behind CWM’s upstairs RnD makeover! View the PDF: Inside CWM Newsletter – Winter 2023/24 Edition |
Inside CWM Newsletter – Winter 2023/24
In the 2022/23 edition of Inside CWM, look back at the last 50+ years from CWM’s COO Bill Baraglia. Find out who won at CWM’s 43rd annual Golf Outing. Catch up on CWM employee bragging rights. View pictures from CWM’s Summer Luncheon. Welcome new employees to CWM, while also recognizing the Outstanding Performers of the Month for all of 2022. And learn what CWM is doing to keep the environment safe. |
Inside CWM Newsletter – 2022/23
In the Summer 2022 edition of Inside CWM, get to know CWM’s Production Manager Jim Reitenbach as he reflects on his 40 years of experience and how things have changed. Find out the 7 Reasons to Keep Die Casting Projects in the USA. Take a look at Margo’s “CWM Zoo” in our #TBT Animal Corner. You can also read about CWM employees who are taking the time to celebrate the good things that happened to them and their families over the summer! Meet CWM’s two Fútbol clubs, and get an update on CWM’s Scholarship recipients who are currently in school! Don’t forget to meet CWM’s “new” employees and compete in CWM trivia and see how much you know about the history of CWM! |
Inside CWM Newsletter – 2022 Summer
In the Spring 2022 edition of Inside CWM, we celebrate 85 years in business! You can also Learn about the Benefits of High-Volume Production. Meet the “new” CWM team members and our Summer Interns and see who retired in 2022. We throw things back to the CWM 75th anniversary party with some pictures. Learn about CWM’s most recent Green Initiatives — including initiating a new Styrofoam recycling program. Find out what happened at CWM’s 42nd Annual Golf Outing. And see who won the CWM Bracket Challenge and what charities they donated to. |
Inside CWM Newsletter – 2022 Spring
In the Winter 2021/22 edition of Inside CWM, learn about the opportunities provided by CWM through the Harper Scholarship Program, take a look at CWM’s Most Outstanding Performers of the Month for each month last year, our CWM Outstanding Performer of the year for 2021, and find out how CWM is starting to use automation to help improve safety! That and so much more in the latest CWM Newsletter! View the PDF: Inside CWM Newsletter – 2021/22 Winter |
Inside CWM Newsletter – 2021/22 Winter
In the Summer 2021 edition of Inside CWM, read about how CWM took home NADCA and IMA industry awards. Read about a CWM team member who retired from the Navy after 20 years of service. Also, learn about CWM’s new 1000-Ton IDRA Machine that is now fully operational. Check out some pictures of CWM employees “getting back to normal.” and welcome “new” employees and say goodbye to retired CWM’ers! We also throw things back to the 1970s, ’80s, and ’90s to take a look at some old parts CWM produced. View the PDF: Inside CWM Newsletter – 2021 Summer |
Inside CWM Newsletter – 2021 Summer
In the Spring 2021 edition of Inside CWM read a perspective article from a former CWM intern turned full-time employee for the last 8 years. Also, read about The Future of Die Casting in One Word: Sustainability. CWM also says goodbye to Ted Bystryk who is Retiring after nearly 50 years at CWM. You can also meet the New CWM Employees and learn about our recent Promotion. And see how CWM got Vaccinated! View the PDF: Inside CWM Newsletter – 2021 Spring |
Inside CWM Newsletter – 2021 Spring
In the 2020 winter Inside CWM, take a look back over the last 60+ years in the Die Cast industry by CWM Chairman, Walter Treiber. We also recognize CWM’s Outstanding Performers of the Month & Year. We have some fun with CWM Pet Superlatives and see who won CWM employee service awards in 2020. We also take some time for some “Employee Bragging Rights” – an update on some CWM’ers and their families and find out how “CWM Gives Back” in 2020 – Toys-for-Tots and CWM. View the PDF: Inside CWM Newsletter – 2020 Winter |
Inside CWM Newsletter – 2020 Winter
In this issue you will find the following stories: CWM’s response to COVID-19 along with a letter from President & CEO Eric Treiber. Customer Care/Fulfillment Manager’s “Dream Farm”. CWM’s website and new product showcase redesign. CWM’s community vegetable garden. See “Throwback Thursday” pictures of some of our longest-tenured employees. Get to know new employees and bid farewell to retirees. CWM’s 40th Annual Golf Outing. View the PDF: Inside CWM Newsletter – 2020 Summer |
In this issue you will find the following stories: CWM Welcomes New Employees and celebrates Retirements. CWM And Aerosonic Take Flight with NADCA Award. CWM New Machinery: Idra Die Casting Machine. Internship Program Offers Real-World Experience to Students. Margo Higgins Opens Home and Heart to Third Rescue Dog. 2019 Employees of the Month. View the PDF: Inside CWM Newsletter – 2020 Spring |
Inside CWM Newsletter – 2020 Spring
In this issue you will find the following stories: CWM Adds New Members to the Team. Employee Promotions. CWM Invests in Robotics and Automation. 2019 Luncheon and Take your Child to Work Day pictures. CWM Educational Tour. 2019 NADCA Meeting Notes. 2018 Employees of the Month and Employee of the Year. CWM Takes Recycling to New Levels. View the PDF: Inside CWM Newsletter – 2019 Spring |
Inside CWM Newsletter – 2019 Spring
In this issue you will find the following stories: 2017 Employees of the Month CWM Gives Tours to Local Educational Institutions 5 Cultural Pillars CWM Team Members and Upcoming Graduations Long Service Awards CWM Adds New Members to the Team Retirements and Employee Promotions. View the PDF: Inside CWM Newsletter – 2018 Spring |
Inside CWM Newsletter – 2018 Spring
In this issue you will find the following stories: CWM adds new members to the team. Happy retirement wishes to 3 employees. CWM Gives Back: Guatemalan Relief from Volcanic Eruption. CWM and Crossbow Manufacturer Hit the Target with a NADCA Design Award. Fenton High School: 2018 Business Partner of the Year. 2018 Annual Health Fair View the PDF: Inside CWM Newsletter – Fall 2018 |
Inside CWM Newsletter – Fall 2018
In this issue you will find the following stories: New Employees, Retirements, Condolences, NEW CWM Guides, Design Awards, Perspectives, CWM Investments, Health Fair 2017, Charitable Efforts, CWM and the Morton Arboretum, and more! View the PDF: Inside CWM Newsletter – 2017 Winter |
Inside CWM Newsletter – 2017 Winter
In this issue you will find the following stories: Anonymous Words, New Employees, Fishing Success, promotions, CWM “Helping Hands”, Annual Picnic, Internships, Annual Golf Outing, Scholarships, and more! View the PDF: Inside CWM Newsletter – 2017 Summer |
In this issue you will find the following stories: Chairman’s Statement on 80th Anniversary, CWM a Part of Cubs History, 2016 Employees of the Month/Year, Long-Time Service Awards, CWM-Fenton Partnership, CWM Helping Hands, and more! View the PDF: Inside CWM Newsletter – 2017 Spring |
Inside CWM Newsletter – 2017 Spring
In this issue you will find the following stories: Die Casting Design Awards for CWM, New Fanuc Robot at CWM, National Sales Conference, Annual Picnic, Ted Bystryk Celebrates 43 Years at CWM, Marketer Goes for Pro in Her Competitive Kayaking Debut, CWM Soccer Team Champion Coaches Children’s Soccer League, and more! View the PDF: Inside CWM Newsletter – 2016 Fall |
Inside CWM Newsletter – 2016 Fall
In this issue you will find the following stories: CWM Scholarship Recipient Receives Prestigious Fellowship, High School Students Shadowing Engineers, CWM Soccer Team Takes Home the Championship, The Gift of Giving: Andrews-Belmonte family, CWM’s Culture of Giving, information about the incoming summer intern, new machinery and more! View the PDF: Inside CWM Newsletter – 2016 Spring |
Inside CWM Newsletter – 2016 Spring
In this issue you will find the following stories: 4 Ways to Use GoPro, 46 Years at CWM, Bragging Rights, Annual Golf Outing, CWM Addresses Critical Industry Issues to Congress, and more! View the PDF: Inside CWM Newsletter – 2015 Fall |
Inside CWM Newsletter – 2015 Fall
In this issue you will find the following stories: Promotions, New Year’s Resolutions, New Equipment, CWM Educational Tour, Holiday Luncheon 2015, CWM Renovations, and more! View the PDF: Inside CWM Newsletter – 2015 Spring |
Inside CWM Newsletter – 2015 Spring
In this issue you will find the following stories: New Equipment, An Addition to the CWM “Zoo”, National Sales Conference 2014, CWM’s Organic Garden, Take Your Child to Work Day Recap, and more! View the PDF: Inside CWM Newsletter – 2014 Fall |
Inside CWM Newsletter – 2014 Fall
In this issue you will find the following stories: Employee Picnic, CWM’er Elected to CAAGC, Chin-Ups for Charity, Service Awards, and more! View the PDF: Inside CWM Newsletter – 2014 Spring |
Inside CWM Newsletter – 2014 Spring
In this issue you will find the following stories: Employee Picnic, CWM’er Elected to CAAGC, Chin-Ups for Charity, Service Awards, and more! View the PDF: Inside CWM Newsletter – 2013 Spring |
Inside CWM Newsletter – 2013 Spring
In this issue you will find the following stories: CWM Commemorates a Proud History, CWM Promoting Health, Defining New Purpose with Untapped Talent, and more! View the PDF: Inside CWM Newsletter – 2012 Winter |
Inside CWM Newsletter – 2012 Winter
In this issue you will find the following stories: CWM’s 75th Anniversary, Get Social with CWM, CWM Scholarship helps Employee’s Daughter, A Rising Interest in a Downhill Sport, CWM Hosts President’s Forum, and more! View the PDF: Inside CWM Newsletter – 2012 Summer |
Inside CWM Newsletter – 2012 Summer
In this issue you will find the following stories: Message from the President, Bring Your Child to Work Day, CWM Global Sales, and more! View the PDF: Inside CWM Newsletter – 2011 Summer |
Inside CWM Newsletter – 2011 Summer
In this issue you will find the following stories: Home Grown Soccer Team Nets CWM Support, Scholarship Opportunity, Going the Distance, What’s Your Health IQ?, and more! View the PDF: Inside CWM Newsletter – 2011 Spring |
Inside CWM Newsletter – 2011 Spring
In this issue you will find the following stories: 30th Annual golf Outing, Summer Picnic, Employees of the Month, New Employees, Sales Meeting. View the PDF: Inside CWM Newsletter – 2010 Fall |
Inside CWM Newsletter – 2010 Fall
In this issue you will find the following stories: Eric Treiber Takes the Helm, “Hall of Fame” Employees Honored, CWM Steps Up Environmental Efforts, and more! View the PDF: Inside CWM Newsletter – 2010 Winter |
Inside CWM Newsletter – 2010 Winter
In this issue you will find the following stories: CWM wins 4 awards, Walter Treiber Celebrates 50 Years at CWM, Employees of the Month, Health Fair details, and more! View the PDF: Inside CWM Newsletter – 2009 Fall |
Inside CWM Newsletter – 2009 Fall
In this issue you will find the following stories: Employee of the Year, 24 CWM Employees Honored for Tenure, Promotions, Selecting the Best Custom Die Caster for Your Next Project, and more! View the PDF: Inside CWM Newsletter – 2009 Spring |
Inside CWM Newsletter – 2009 Spring
In this issue you will find the following stories: Investment in New CNC Centers, going Green, Outstanding Safety Award, Annual Golf Outing Pictures, and more! View the PDF: Inside CWM Newsletter – 2008 Fall |
Inside CWM Newsletter – 2008 Fall
In this issue you will find the following stories: New CNC Centers Added for Higher Machine Speeds, Announcement of New QA Planning Manager position, 21 Veterans Receive 10-Year to 30-Year Service Awards, and more! View the PDF: Inside CWM Newsletter – 2008 Spring |
Inside CWM Newsletter – 2008 Spring
In this issue you will find the following stories: CWM Celebrates 70 Years, Walter Treiber Retires from IMA Presidency, Annual Golf Outing Pictures, and more! View the PDF: Inside CWM Newsletter – 2007 Fall |
Inside CWM Newsletter – 2007 Fall
In this issue you will find the following stories: Employee of the Year, 21 CWM’ers receive Service Awards, Web Resources for OEM Buyers, and more! View the PDF: Inside CWM Newsletter – 2007 Spring |
Inside CWM Newsletter – 2007 Spring
In this issue you will find the following stories: Observing 9/11 5th Anniversary, implementation of Lean Manufacturing, Promotion of Two Case Studies, Annual CWM Golf Outing in Bloomingdale, and more! View the PDF: Inside CWM Newsletter – 2006 Fall |
Inside CWM Newsletter – 2006 Fall
In this issue you will find the following stories: Employee of the Year, 10 CWM Employees Receive Long-Time Service Awards, Walter Treiber Leads IMA to 1st Conference in China, CWM’s Eagle Award, and more! View the PDF: Inside CWM Newsletter – 2006 Spring |
Inside CWM Newsletter – 2006 Spring
In this issue you will find the following stories: Redesigned CWM Website, Brian Andrews Promoted to VP of CNC Production, TCP Finish Meets EPA Standards, Tribute to Eric Treiber from 3 Sisters, and more! View the PDF: Inside CWM Newsletter – 2005 Fall |
Inside CWM Newsletter – 2005 Fall
In this issue you will find the following stories: Eric Treiber Becomes 3rd Generation to Head CWM as President & COO, Salesman of the Year, CWM Paper Presented at 3rd EPA International Conference, and more! View the PDF: Inside CWM Newsletter – 2005 |
Inside CWM Newsletter – 2005
We are at a breaking point when it comes to overproducing plastics. Check out this special OEM Tech Brief to learn about the environmental advantages of using easily recyclable materials like aluminum, magnesium, or zinc instead of plastic. View the PDF: Die Casting’s Environmental Advantage over Plastics |
Die Casting’s Environmental Advantage over Plastics
This 3-page article was taken from NADCA’s Die Cast Engineer magazine (Nov 2016) and describes primary and secondary aluminum pricing and the overall trends and challenges which the aluminum alloys market experiences in North America. View the PDF: The Market for Aluminum Alloys in North America: Trends and Challenges |
The Market for Aluminum Alloys in North America: Trends and Challenges
Paul Midler, with a background in Chinese studies and history– and hands-on experience working for years in China with Chinese supplier manufacturers– has written a valuable new book, “Poorly Made in China,” Any North American OEM considering offshore sourcing will want to be familiar with the information this interesting businessman-author documents. View the PDF: Book Review: “Poorly Made in China” |
Book Review: “Poorly Made in China”
When production runs for a machined component part increase, advanced net-shape die casting can offer substantial unit cost savings compared to part machining to specifications. Such cost reductions are being achieved for a wide variety of machined part applications in a range of alloys and part sizes. In the case of many small precision parts, the net-shape 4-slide miniature die casting process can be used to replace a brass machined part at no sacrifice in mechanical properties for significant savings at even low production volumes. This Tech Brief discusses the many advantages of machining-to-die casting conversions in addition to unit cost savings. View the PDF: Converting Machined Parts to Die Casting |
Converting Machined Parts to Die Casting
Two-Part Tech Brief: Part 1 outlines findings of recent Design News Study of design engineers: Salary gains, but with added duties. Part 2 presents a tailored listing of key initial resources in this DC2 Design Center for OEMs considering the die casting process, with direct download links to the described documents. Three DC2 OEM lists are presented, based on one’s design project role and process background. View the PDF: Design News Engrg Survey & Key DC2 OEM Resources |
Design News Engrg Survey & Key DC2 OEM Resources
When a design is started from a clean sheet of paper, the designer must disassociate the design constraints from the materials and processes traditionally employed. This 2-page paper reviews the path to the optimum cost-effective results. View the PDF: Developing an Optimum Product Design |
Developing an Optimum Product Design
Latest information on Trivalent chromium which is now a proven alternative to hexavalent chromium coatings and meets new U.S. and European Union environmental mandates. Economical, with a cosmetically pleasing finish, it offers high corrosion resistance for CWM Al, Mg & Zn die castings. View the PDF: EPA-Compliant Chromate for Al, Mg & Zn Parts |
EPA-Compliant Chromate for Al, Mg & Zn Parts
This article provides insight on and describes the period of transition from an offshore manufacturing source to an onshore manufacturer. This article is taken from “Global Manufacturing” online publication. View the PDF: Getting on Course After Onshoring |
Getting on Course After Onshoring
This 10-point OEM checklist can be a helpful guide to making the optimum supplier decision for successful results in producing a new housing or component as a custom die casting in aluminum, magnesium, or zinc. View the PDF: How to Select the Best Custom Die Caster |
How to Select the Best Custom Die Caster
Financial Times article describes record robot sales by China to automate industrial processes for the manufacturing industry. An additional CWM article explains the benefits of the recent robot acquisitions. View the PDF: Special Industrial Robotics Issue |
Special Industrial Robotics Issue
A 2-page technical paper. It offers the facts to five ‘known’ misconceptions about magnesium die casting. It also discusses the unique properties that can be gained from die casting with magnesium. View the PDF: Still Believe These Five Magnesium Myths? |
Still Believe These Five Magnesium Myths?
Charles Fishman, award-winning investigative and magazine journalist writing in the Atlantic magazine, explores what he calls a startling, sustainable, just-getting-started return of industry to the United States. After years of offshore production, U.S. companies are moving much of their far-flung manufacturing operations back home. General Electric is an early example, but it is not alone. Whirlpool, from China to Ohio; Otis, from Mexico to South Carolina; even Wham-O, from China to California. This Tech Brief is a condensation of his recent in-depth article with reasons for these major production shifts that he labels “The Insourcing Boom.” View the PDF: The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S |
The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S
This white paper is a 6-page excerpt of an article that describes the current state of the United States Aluminum Casting Industry as it relates to Aluminum Die Casting. This article was written by The Folk Group. (Truncated Version) View the PDF: The U.S. Aluminum Casting Industry |
The U.S. Aluminum Casting Industry
In this issue you will find the following stories: New Employees, Retirements, Condolences, NEW CWM Guides, Design Awards, Perspectives, CWM Investments, Health Fair 2017, Charitable Efforts, CWM and the Morton Arboretum, and more! View the PDF: USA Today: Manufacturing Heading Back to USA? |
USA Today: Manufacturing Heading Back to USA?
If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a lightweight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands-down choice! View the PDF: The Plastic vs Die Casting Process Decision |
The Plastic vs Die Casting Process Decision
Describes how the use of this advanced in-house software technology, with simulated 3D computer metal-flow animations, can help assure 1st-shot success and die cast production repeatability. The benefits of further economical tooling design modifications can be clearly revealed prior to tooling construction. View the PDF: How Magmasoft Process Simulation Lowers Costs |
How Magmasoft Process Simulation Lowers Costs
Find out how the robotics industry is impacting not only die casting, but a wide array of other industries as well. In this whitepaper, you’ll learn about the difference between traditional robots and collaborative robots, the two types of robots used by CWM. View the PDF: Industry Spotlight: Robotics |
Industry Spotlight: Robotics
With the demand for Hybrid Electric and Electric Vehicles on the rise, automakers are looking for ways to reduce vehicle weight. They want to improve overall performance, increase fuel or battery efficiency, and extend driving range without sacrificing design or safety. The answer to their problems just might be High-Pressure Die Casting. View the PDF: Electric Vehicles: Component Manufacturing Using the High-Pressure Die Casting Process |
Electric Vehicles: Component Manufacturing Using the High-Pressure Die Casting Process
As a steno writing machine is compact and portable, the use of magnesium provided a lightweight, yet higher quality feel than plastic. The highly cosmetic finishing provides the flawless appearance which the customer was going for. View the PDF: The CWM Difference: Mg AZ91D Steno Writer Parts |
The CWM Difference: Mg AZ91D Steno Writer Parts
When a design is started from a clean sheet of paper, the designer must disassociate the design constraints from the materials and processes traditionally employed. This 2-page paper reviews the path to the optimum cost-effective results. View the PDF: Developing an Optimum Product Design |
Developing an Optimum Product Design
More densely-packed housings, faster processing speeds, and new EMI regulations call for changes in electronic housing designs. This paper frames the EMI shielding challenge, the importance of attention to shielding concerns well before the prototyping stage, and outlines the pros and cons of shielding alternatives in metal and plastic housings. View the PDF: Superior EMI Shielding with Die Cast Housings |
Superior EMI Shielding with Die Cast Housings
Step-by-step tutorial for a typical electronic enclosure design optimized for die casting takes the product designer through die casting design decisions applying recommended engineering principles appropriate to a range of similar design projects. Published by NADCA. View the PDF: Tutorial: Electronic Enclosure Design for Die Casting |
Tutorial: Electronic Enclosure Design for Die Casting
Step-by-step tutorial for a redesigned bracket design optimized for die casting takes the product designer through die casting design and redesign decisions applying recommended engineering principles appropriate to a range of similar redesign projects. Published by NADCA. View the PDF: Tutorial: Redesigning a Steel Bracket for Die Casting |
Tutorial: Redesigning a Steel Bracket for Die Casting
Presents the important factors that can affect the outcome of the final appearance of your die cast component when its surface finish is a critical issue. This narrated webinar will aid an understanding of the various finish options, and how their uses and limitations can make the difference between successful product development and costly results. 49 minutes. |
Surface Finishes for Die Casting
This overview for OEM designers and specifiers is a refresher for those OEM product design engineers, buyers, and purchasing managers already familiar with die casting; and for those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
The Die Casting Process: An OEM Designer’s Overview
Presents the facts on why multi-slide, miniature zinc die casting is the preferred choice for small precision components. It enables product designers to learn how this specialized die casting process can substantially reduce component costs and provide optimal precision to a new project design or a conversion from an existing process. |
The Miniature Zinc Die Casting Advantage
6-page guide outlines 10 key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. These specific planning steps aid in integrating the realities of die cast manufacturing. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
10 Ways to Reduce the Costs of Die Cast Parts
The central component for a newly developed archery bow for serious young archers is a high-tech Al die casting produced to precision tolerance specifications and machined look and feel of a “hog out.” Delivered at the targeted market price, on a tightened time schedule to tie-in with promotional book and film release dates. NADCA Die Casting Award of Excellence winner. (Includes photos) View the PDF: Al Archery Bow NADCA Die Casting Award Winner |
Al Archery Bow NADCA Die Casting Award Winner
2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties, and nominal chemistry for its Al, Mg & Zn alloy capabilities. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
CWM Al, Mg & Zn Die Cast Production Specs
16-page, full-color comprehensive brochure on Chicago White Metal Casting capabilities in the most widely specified die casting alloys— Al, Mg & Zn. From design assistance through production, post-casting machining, surface finishing, and final product assembly. Detailed overview covers the experience, advanced technologies, and ISO 9001 & 14001 registered management systems that make CWM the cost-effective choice for net- and near-net-shape die cast parts. Includes case examples. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
CWM Comprehensive Die Casting Capabilities Brochure
Updated and expanded 16-page reference to the major design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among key design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. View the PDF: Design & Specification Guide for Custom Die Castings |
Design & Specification Guide for Custom Die Castings
An exercise in a step-by-step redesigning a part from a welded steel assembly to a die casting, applying recommended engineering principles, and the 1999 NADCA Product Standards for optimum die casting results. View the PDF: Design of a Bracket for Die Casting Production |
Facts on the material recycling infrastructure long in place for die cast metal parts and recyclability questions designers should ask in selecting materials and manufacturing processes for “green” component design. View the PDF: Designing for Servicing & Recyclability |
Designing for Servicing & Recyclability
An introductory guide to developing the optimum component configuration for cost-effective die cast processing. It provides an overview of design features that enable the designer to capitalize on the inherent advantages of net-shape die cast production. View the PDF: Designing Optimum Part Shapes |
Designing Optimum Part Shapes
Certain design and production myths regarding die casting may be crippling material and manufacturing decision making. This discussion, by CWM’s V.P. of Engineering, takes a look at today’s die casting design realities. View the PDF: Die Cast Design Myths Can Cripple Optimum Decisions |
Die Cast Design Myths Can Cripple Optimum Decisions
Presents data on heat sink materials comparisons and the strengths and weaknesses of heat sinks produced as stampings, extrusions, and die castings. Of special interest to designers less familiar with integral incorporation of heat sinks into a housing design or the potential of custom die cast sink designs View the PDF: Die Cast Heat Sink Can Be a Cost-Effective OEM Choice |
Die Cast Heat Sink Can Be a Cost-Effective OEM Choice
Computer workstations from Silicon Graphics incorporated a zinc die cast rear cap frame, which combined important structural function with superior cosmetic appearance. The Zn die cast component, selected for its excellent strength, rigidity, EMI shielding characteristics, and part consolidation potential, was the first use by the company of a die casting in one of their workstation computers. View the PDF: Die Cast Zn for Key Computer Structural Component |
Die Cast Zn for Key Computer Structural Component
Preplanning Guide to aid OEMs considering custom die cast part production and reviewing existing literature. Organizes selected industry and CWM design resources into a 7-step sequence for the planning process. The source of each die casting design and production bulletin, tech brief, guide, checklist, and reference manual is listed, with many available for Web downloading or forwarding by Email. Bulletin contains direct Web links to aid access or requests for all listed documents. View the PDF: Die Casting Design & Production Preplanning Guide |
Die Casting Design & Production Preplanning Guide
The first motocross design produced on American soil in 20 years features many rule-breaking design innovations, such as its “sweet,” solid shifting clutch, made with two high-tech Al die castings. The Al hub has 35 gear teeth cast to zero draft. The crankshaft and engine cover are AZ91D hot-chamber mag die castings, providing strength and lightweight. View the PDF: Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft |
Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft
Project managers for this satellite positioning system designed an Mg die cast enclosure as advanced as the new technology inside: ultra-rugged; lightweight for field use; waterproof; dustproof, with fail-safe EMI shielding. View the PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg |
GPS Satellite Tracker Unit in Rugged, Lightweight Mg
Designed as part of an advanced digital video processing and control system, Sony engineers specified “perfect parts” for their new professional video camera. CWM high-tech die casting was selected to produce 11 aluminum and hot-chamber magnesium housing components for the new camera. Superior as-cast surfaces were primary specifications. View the PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg |
High-Tech Al & Mg for Advanced Video Imaging System
Two intricate Al die castings are the heart of a vaporizer-regulator for propane and natural gas vehicles, winning an industry award for their casting excellence. Meeting important thermal and weight specs, the two castings that make up the unit have channel walls, and the spaces between them, that measure 0.040 in. (1.016 mm) thick. View the PDF: Intricate Al Die Cast Propane Vaporizer-Regulator |
Intricate Al Die Cast Propane Vaporizer-Regulator
World leader in global positioning systems selected Mg die castings for the key housing components in their new optical surveying instrument. Machined parts were rejected as cost prohibitive; plastic would not provide the required stiffness for highly accurate readings. View the PDF: Key High-Tech Mg Parts for Optical Survey System |
Key High-Tech Mg Parts for Optical Survey System
This presentation will aid OEM product designers, engineers, and specifiers with valuable, practical guidelines for assuring sound design-for-manufacturing decisions prior to freezing their designs destined for die casting production. View the PDF: Leveraging DFM Prior to Design Commitment |
Leveraging DFM Prior to Design Commitment
For users of machined parts looking for opportunities to reduce part costs while improving existing designs, with lower environmental impacts. Narrated webinar covers die cast conversion benefits and when such conversions are and are not advantageous. Tips on how best to make the transfer to an optimized die cast part. Covers conversion design considerations, alloys, and surface finishes— with case studies. 30 minutes. Watch: Machining to Die Casting: A Guide to Conversion Webinar |
Machining to Die Casting: A Guide to Conversion
Outlines EMI/RFI shielding requirements for electronic assemblies. Presents relationships between common measures of shielding, advantages of die castings in general, and mag die castings in particular, for electronic enclosure shielding. Prepared by Norsk Hydro Magnesium. View the PDF: Magnesium EMI Shielding Characteristics |
Magnesium EMI Shielding Characteristics
Two Mg 12 x 17 in. precision die cast housing walls for an all-in-one multi-media desktop medical imager provide lightweight, multiple functions, and reduced part counts. Each high-tech hot-chamber mag die casting delivers 25 tight-toleranced features as-cast. View the PDF: Medical Imager Mg Multi-function Housing Walls |
Medical Imager Mg Multi-function Housing Walls
First professional digital camera in a magnesium die cast housing, jointly developed by Kodak and Nikon. Mag, selected over the usual alternative of plastic encasing a stamped metal body or an Al casting, provides ruggedness, lightweight, and the quality feel of metal. View the PDF: Mg Die Cast Professional Digital Camera Case |
Mg Die Cast Professional Digital Camera Case
Eight precision components form the self-contained display and keypad plus probe connector unit for a new all-digital portable ultrasound system. A total component weight of 1.725 lbs. makes the unit lighter than a molded plastic design, with greater drop strength. Winner of a “Design Award of Excellence” from the International Magnesium Assn. View the PDF: Mg Die Cast Ultrasound Portable Workstation Housing |
Mg Die Cast Ultrasound Portable Workstation Housing
New Mg die cast support structure for an advanced rear view automotive mirror is now being produced in a high-pressure hot-chamber mag die casting machine with trimming operations eliminated. Employing “in-die de-gating,” two-stage ejection technology, borrowed from miniature Zn die cast production, savings include eliminating the trim die build. (Includes photos) View the PDF: Mg IMA Process Technology Award for Auto Mirror |
Mg IMA Process Technology Award for Auto Mirror
This in-depth White Paper from the North American Die Casting Assn. details of how collaborative engineering between OEM engineers and custom die caster engineering can result in improved production efficiencies and reduced part costs. The case study method is used to discuss cost-saving opportunities for existing parts at the point of tooling replacement or required product design revisions, as well as for clean sheet designs. View the PDF: NADCA Collaborative Engineering White Paper |
NADCA Collaborative Engineering White Paper
Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. View the PDF: NADCA Design Manual: Intro & Content |
NADCA Design Manual: Intro & Content
Cross-reference chart for former superseded American Die Casting Institute (ADCI) and superseded North American Die Casting Assn. #401 (NADCA) Product Standards and current NADCA Product Standards. (2015) View the PDF: NADCA-ADCI Standards Cross-Reference Chart |
NADCA-ADCI Standards Cross-Reference Chart
NADCA updated comparison reviews die cast and plastic parts on material availability and recycling, material properties, design tolerances, and material costs. Examines the fact that plastic materials that offer higher strength than mag alloys have material costs that are at least four times greater than magnesium. View the PDF: NADCA: Comparison of Mag Die Casting & Plastic Parts |
NADCA: Comparison of Mag Die Casting & Plastic Parts
Presentation of “Standard” and “Precision” tolerances as outlined in the latest NADCA Product Standards Manual, plus outline of Coordinate Dimensioning vs the advantages of the GD&T framework for specifying die cast parts. View the PDF: NADCA: Coordinate vs Geometric Dimensioning Intro |
NADCA: Coordinate vs Geometric Dimensioning Intro
Key factors in specifying the production and surface finishing of die cast parts, based on NADCA Product Standards Manual guidelines. Helps assure clearer communication between OEM purchaser and die caster. (2015) View the PDF: NADCA: Die Cast Production & Finishing Checklists |
NADCA: Die Cast Production & Finishing Checklists
A concise outline of the specific facts regarding how die casting manufacturing efficiency contributes to ecological sustainability: All die casting metals can be recycled and reused with no loss in material properties, resulting in the vast majority of die castings made with post-consumer metals which, in addition, require far less energy to reprocess than virgin materials. In the production of non-ferrous metal castings, die casting is the most energy-efficient casting process, with reusable molds and very high production rates resulting in highly-efficient energy usage. The carbon footprint of the die casting industry is among the lowest among producers of net- or near-net shape products and component parts—far less than that of plastic injection moldings. View the PDF: NADCA: For Efficient Manufacturing, Look to Die Casting |
NADCA: For Efficient Manufacturing, Look to Die Casting
Die castings offer exceptional design freedom while at the same time achieving excellent mechanical properties for a product component. Selected features should be designed to enhance casting quality and avoid unnecessary casting costs. This article offers details on key points to consider in optimizing the cost-performance equation for a die cast part. View the PDF: NADCA: Pointers for Designing Die Castings |
NADCA: Pointers for Designing Die Castings
Illustrated condensed overview of the basic contents of the die casting industry’s authoritative “Product Specification Standards for Die Castings” reference manual, as originally established in 1997. View the PDF: NADCA: Product Standards Manual Overview |
NADCA: Product Standards Manual Overview
Aid to understanding die caster tooling requirements for optimum part production: Updated checklists for both new dies, and existing die casting dies to be transferred, based on NADCA Product Standards Manual guidelines. View the PDF: NADCA: Tooling Checklists for Die Casting Dies |
NADCA: Tooling Checklists for Die Casting Dies
Ruggedness, impact strength, and light weight were key requirements for this handheld field unit for on-site analysis of voice and data. Specifications were met by this hot-chamber Mg die casting housing, which survives 4-foot drop tests to concrete. View the PDF: Only Mg Met Strength-Weight Specs for Voice/Data Unit |
Only Mg Met Strength-Weight Specs for Voice/Data Unit
4-page condensed overview of Chicago White Metal Casting capabilities in Al, Mg, and Zn from front-end assistance, prototyping to part finishing, and assembly. Summarizes CWM’s experience, advanced technologies, and ISO 9001 & 14001 registered management systems. View the PDF: Overview of CWM Die Casting & Production Capabilities |
Overview of CWM Die Casting & Production Capabilities
Handheld fiber optic cable analyzer introduced in a high-tech magnesium die cast housing with elastomer overmolding. Innovative case, claimed to be the first overmolding of a complex die casting, offers improved performance over plastic at a 20% saving. View the PDF: Portable Die Cast Mg Case with Elastomer Overmolding |
Portable Die Cast Mg Case with Elastomer Overmolding
Overmolding of a die cast enclosure allows product advantages beyond the soft-touch characteristics of elastomers. Tech Brief outlines design considerations that should be addressed by the design engineer planning a marriage of die casting and elastomer overmolding. View the PDF: Preliminary Guide to Overmolding of Die Cast Parts |
Preliminary Guide to Overmolding of Die Cast Parts Condensed overview for OEM product designers and engineers on Miniature Zinc & ZA-8 custom die casting for the cost-effective production of small, complex structural components. View the PDF: Primer on Miniature Zinc & ZA-8 Die Casting |
Primer on Miniature Zinc & ZA-8 Die Casting
Presentation to aid efficiency, functionality, and cost savings in the design and production of custom die castings. This narrated webinar focuses on helping effectively capitalize on today’s advanced die casting capabilities to improve performance and lower the costs of their custom components. 1 hour. |
Product Solutions Through Die Casting
A value analysis of alternate production efficiencies for a low-volume CNC machined brass small component for a medical device resulted in a miniature zinc net-shape die cast replacement at a 500% unit cost saving. View the PDF: Replacement for Machined Brass at a 500% Savings |
Replacement for Machined Brass at a 500% Savings
A wireless remote laser unit to aid pipelaying accuracy and efficiency is claimed to be the most powerful laser device of its kind allowed by law. The new model offers an Al die cast metal housing to meet extreme, rugged field conditions, difficult for plastic housings to survive. View the PDF: Rugged Al Die Cast Laser Housing Outperforms Plastic |
Rugged Al Die Cast Laser Housing Outperforms Plastic
This advanced spotting scope, offering the sharpest, brightest viewing at distances greater than possible with premium binoculars, has impressive housing specifications: lightweight portability, absolute ruggedness, 100% waterproof construction— it is nitrogen filled and guaranteed for life. Its central housing is produced as a hot-chamber magnesium high-precision die casting, weighing just 8.0 oz. (226.8 gm) with thin-wall sections as narrow as 0.039 in. (1.0 mm). View the PDF: Rugged Mg Spotting Scope Die Casting Award |
Rugged Mg Spotting Scope Die Casting Award
Cross-reference chart for former superseded American Die Casting Institute (ADCI) and superseded North American Die Casting Assn. #401 (NADCA) Product Standards and current NADCA Product Standards. (2015) View the PDF: NADCA-ADCI Standards Cross-Reference Chart |
Preplanning Guide to aid OEMs considering custom die cast part production and reviewing existing literature. Organizes selected industry and CWM design resources into a 7-step sequence for the planning process. The source of each die casting design and production bulletin, tech brief, guide, checklist, and reference manual is listed, with many available for Web downloading or forwarding by Email. Bulletin contains direct Web links to aid access or requests for all listed documents. View the PDF: Die Casting Design & Production Preplanning Guide |
Die Casting Design & Production Preplanning Guide
Ruggedness, impact strength, and light weight were key requirements for this handheld field unit for on-site analysis of voice and data. Specifications were met by this hot-chamber Mg die casting housing, which survives 4-foot drop tests to concrete. View the PDF: Only Mg Met Strength-Weight Specs for Voice/Data Unit |
Only Mg Met Strength-Weight Specs for Voice/Data Unit
Condensed overview for OEM product designers and engineers on Miniature Zinc & ZA-8 custom die casting for the cost-effective production of small, complex structural components. View the PDF: Primer on Miniature Zinc & ZA-8 Die Casting |
16-page, full-color comprehensive brochure on Chicago White Metal Casting capabilities in the most widely specified die casting alloys— Al, Mg & Zn. From design assistance through production, post-casting machining, surface finishing, and final product assembly. Detailed overview covers the experience, advanced technologies, and ISO 9001 & 14001 registered management systems that make CWM the cost-effective choice for net- and near-net-shape die cast parts. Includes case examples. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
CWM Comprehensive Die Casting Capabilities Brochure
Handheld fiber optic cable analyzer introduced in a high-tech magnesium die cast housing with elastomer overmolding. Innovative case, claimed to be the first overmolding of a complex die casting, offers improved performance over plastic at a 20% saving. View the PDF: Portable Die Cast Mg Case with Elastomer Overmolding |
Guide to developing optimum prototyping strategies for developing and testing component designs prior to final die casting die construction. Discusses prototyping alloys and processes, including new rapid prototyping technologies. View the PDF: Prototyping for Die Casting in All Alloys |
Prototyping for Die Casting in All Alloys
2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties, and nominal chemistry for its Al, Mg & Zn alloy capabilities. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
CWM Al, Mg & Zn Die Cast Production Specs
A value analysis of alternate production efficiencies for a low-volume CNC machined brass small component for a medical device resulted in a miniature zinc net-shape die cast replacement at a 500% unit cost saving. View the PDF: Replacement for Machined Brass at a 500% Savings |
Replacement for Machined Brass at a 500% Savings
8-page condensed resource on evaluating finishing alternatives and optimizing component finishing decisions for Al, Mg, and Zn die cast products. Features a comparison table rating 32 surface coatings on relative cost, appearance, wear, and corrosion resistance; Presents recommended finishing for a range of typical die cast components. View the PDF: Quick Guide to Surface Finishing for Al, Mg & Zn Parts |
Quick Guide to Surface Finishing for Al, Mg & Zn Parts
Updated and expanded 16-page reference to the major design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among key design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. View the PDF: Design & Specification Guide for Custom Die Castings |
Design & Specification Guide for Custom Die Castings
A wireless remote laser unit to aid pipelaying accuracy and efficiency is claimed to be the most powerful laser device of its kind allowed by law. The new model offers an Al die cast metal housing to meet extreme, rugged field conditions, difficult for plastic housings to survive. View the PDF: Rugged Al Die Cast Laser Housing Outperforms Plastic |
Rugged Al Die Cast Laser Housing Outperforms Plastic
More densely-packed housings, faster processing speeds, and new EMI regulations call for changes in electronic housing designs. This paper frames the EMI shielding challenge, the importance of attention to shielding concerns well before the prototyping stage, and outlines the pros and cons of shielding alternatives in metal and plastic housings. View the PDF: Superior EMI Shielding with Die Cast Housings |
Superior EMI Shielding with Die Cast Housings
Two Al and one Mg die casting Awards were won by CWM for a first-ever triple win for outstanding custom die castings in the annual North American Die Casting Association’s International Die Casting Competition. (Includes photos) View the PDF: 1st-ever Triple Winners in NADCA Die Casting Contest |
1st-ever Triple Winners in NADCA Die Casting Contest
This advanced spotting scope, offering the sharpest, brightest viewing at distances greater than possible with premium binoculars, has impressive housing specifications: lightweight portability, absolute ruggedness, 100% waterproof construction— it is nitrogen filled and guaranteed for life. Its central housing is produced as a hot-chamber magnesium high-precision die casting, weighing just 8.0 oz. (226.8 gm) with thin-wall sections as narrow as 0.039 in. (1.0 mm). View the PDF: Rugged Mg Spotting Scope Die Casting Award |
Rugged Mg Spotting Scope Die Casting Award
Brief overview of surface treatment systems for die cast part protection, decoration, and improving component performance, for all alloys: Al, Mg, Zn, and ZA. View the PDF: Surface Finishing for Die Casting Bulletin |
Surface Finishing for Die Casting Bulletin
The central component for a newly developed archery bow for serious young archers is a high-tech Al die casting produced to precision tolerance specifications and machined look and feel of a “hog out.” Delivered at the targeted market price, on a tightened time schedule to tie-in with promotional book and film release dates. NADCA Die Casting Award of Excellence winner. (Includes photos) View the PDF: Al Archery Bow NADCA Die Casting Award Winner |
Chicago White Metal explores magnesium die casting in this informative webinar. Reviews the unique properties of die casting with magnesium that can be employed in a new design or conversion from another process. The information presented in this webinar is for OEM product designers and engineers who want to understand how magnesium die casting can improve product performance and reduce costs. 50 minutes. |
Magnesium Die Casting: Solutions for Today’s Markets
Certain design and production myths regarding die casting may be crippling material and manufacturing decision making. This discussion, by CWM’s V.P. of Engineering, takes a look at today’s die casting design realities. View the PDF: Die Cast Design Myths Can Cripple Optimum Decisions |
If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a lightweight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands-down choice View the PDF: The Plastic vs Die Casting Process Decision |
The Plastic vs Die Casting Process Decision
Computer workstations from Silicon Graphics incorporated a zinc die cast rear cap frame, which combined important structural function with superior cosmetic appearance. The Zn die cast component, selected for its excellent strength, rigidity, EMI shielding characteristics, and part consolidation potential, was the first use by the company of a die casting in one of their workstation computers. View the PDF: Die Cast Zn for Key Computer Structural Component |
Die Cast Zn for Key Computer Structural Component
A 2-page technical paper. It offers the facts to five ‘known’ misconceptions about magnesium die casting. It also discusses the unique properties that can be gained from die casting with magnesium. View the PDF: Still Believe These Five Magnesium Myths? |
Still Believe These Five Magnesium Myths?
Introductory overview and guide to optimum materials and alternate process selection. It contains a physical and mechanical materials properties comparison chart for the most widely used Al, Mg & Zn die casting alloys. View the PDF: Evaluating Materials & Processes |
Evaluating Materials & Processes
Step-by-step tutorial for a redesigned bracket design optimized for die casting takes the product designer through die casting design and redesign decisions applying recommended engineering principles appropriate to a range of similar redesign projects. Published by NADCA. View the PDF: Tutorial: Redesigning a Steel Bracket for Die Casting |
The first motocross design produced on American soil in 20 years features many rule-breaking design innovations, such as its “sweet,” solid shifting clutch, made with two high-tech Al die castings. The Al hub has 35 gear teeth cast to zero draft. The crankshaft and engine cover are AZ91D hot-chamber mag die castings, providing strength and lightweight. View the PDF: Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft |
Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft
This chart compares the material and physical properties for three popular die casting alloys: aluminum A380, magnesium AZ91D, Zinc #3, and ZA8. Several material properties such as tensile strength, impact, and yield strength can be compared between the three alloys. Physical properties such as density and conductivity can also be examined. View the PDF: Material / Physical Properties Comparison |
Material / Physical Properties Comparison
Outlines EMI/RFI shielding requirements for electronic assemblies. Presents relationships between common measures of shielding, advantages of die castings in general, and mag die castings in particular, for electronic enclosure shielding. Prepared by Norsk Hydro Magnesium. View the PDF: Magnesium EMI Shielding Characteristics |
Magnesium EMI Shielding Characteristics
This presentation will aid OEM product designers, engineers, and specifiers with valuable, practical guidelines for assuring sound design-for-manufacturing decisions prior to freezing their designs destined for die casting production. View the PDF: Leveraging DFM Prior to Design Commitment |
Leveraging DFM Prior to Design Commitment
Project managers for this satellite positioning system designed an Mg die cast enclosure as advanced as the new technology inside: ultra-rugged; lightweight for field use; waterproof; dustproof, with fail-safe EMI shielding. View the PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg |
GPS Satellite Tracker Unit in Rugged, Lightweight Mg
When a design is started from a clean sheet of paper, the designer must disassociate the design constraints from the materials and processes traditionally employed. This 2-page paper reviews the path to the optimum cost-effective results. View the PDF: Developing an Optimum Product Design |
Developing an Optimum Product Design
Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. View the PDF: NADCA Design Manual: Intro & Content |
NADCA Design Manual: Intro & Content
Presentation to aid efficiency, functionality, and cost savings in the design and production of custom die castings. This narrated webinar focuses on helping effectively capitalize on today’s advanced die casting capabilities to improve performance and lower the costs of their custom components. 1 hour. |
Designed as part of an advanced digital video processing and control system, Sony engineers specified “perfect parts” for their new professional video camera. CWM high-tech die casting was selected to produce 11 aluminum and hot-chamber magnesium housing components for the new camera. Superior as-cast surfaces were primary specifications. View the PDF: High-Tech Al & Mg for Advanced Video Imaging System |
High-Tech Al & Mg for Advanced Video Imaging System
Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Aluminum Alloy Data |
NADCA Standards: Aluminum Alloy Data
Presents the important factors that can affect the outcome of the final appearance of your die cast component when its surface finish is a critical issue. This narrated webinar will aid an understanding of the various finish options, and how their uses and limitations can make the difference between successful product development and costly results. 49 minutes. |
Two intricate Al die castings are the heart of a vaporizer-regulator for propane and natural gas vehicles, winning an industry award for their casting excellence. Meeting important thermal and weight specs, the two castings that make up the unit have channel walls, and the spaces between them, that measure 0.040 in. (1.016 mm) thick. View the PDF: Intricate Al Die Cast Propane Vaporizer-Regulator |
Intricate Al Die Cast Propane Vaporizer-Regulator
Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Magnesium Alloy Data |
NADCA Standards: Magnesium Alloy Data
This overview for OEM designers and specifiers is a refresher for those OEM product design engineers, buyers, and purchasing managers already familiar with die casting; and for those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
The Die Casting Process: An OEM Designer’s Overview
World leader in global positioning systems selected Mg die castings for the key housing components in their new optical surveying instrument. Machined parts were rejected as cost prohibitive; plastic would not provide the required stiffness for highly accurate readings. View the PDF: Key High-Tech Mg Parts for Optical Survey System |
Key High-Tech Mg Parts for Optical Survey System
Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Zinc & ZA Alloy Data |
NADCA Standards: Zinc & ZA Alloy Data
Presents the facts on why multi-slide, miniature zinc die casting is the preferred choice for small precision components. It enables product designers to learn how this specialized die casting process can substantially reduce component costs and provide optimal precision to a new project design or a conversion from an existing process. |
The Miniature Zinc Die Casting Advantage
Two Mg 12 x 17 in. precision die cast housing walls for an all-in-one multi-media desktop medical imager provide lightweight, multiple functions and reduced part counts. Each high-tech hot-chamber mag die casting delivers 25 tight-toleranced features as-cast. View the PDF: Medical Imager Mg Multi-function Housing Walls |
NADCA updated comparison reviews die cast and plastic parts on material availability and recycling, material properties, design tolerances, and material costs. Examines the fact that plastic materials that offer higher strength than mag alloys have material costs that are at least four times greater than magnesium. View the PDF: NADCA: Comparison of Mag Die Casting & Plastic Parts |
6-page guide outlines 10 key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. These specific planning steps aid in integrating the realities of die cast manufacturing. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
First professional digital camera in a magnesium die cast housing, jointly developed by Kodak and Nikon. Mag, selected over the usual alternative of plastic encasing a stamped metal body or an Al casting, provides ruggedness, lightweight, and the quality feel of metal. View the PDF: Mg Die Cast Professional Digital Camera Case |
Mg Die Cast Professional Digital Camera Case
A concise outline of the specific facts regarding how die casting manufacturing efficiency contributes to ecological sustainability: All die casting metals can be recycled and reused with no loss in material properties, resulting in the vast majority of die castings made with post-consumer metals which, in addition, require far less energy to reprocess than virgin materials. In the production of non-ferrous metal castings, die casting is the most energy-efficient casting process, with reusable molds and very high production rates resulting in highly-efficient energy usage. The carbon footprint of the die casting industry is among the lowest among producers of net- or near-net shape products and component parts—far less than that of plastic injection moldings. View the PDF: NADCA: For Efficient Manufacturing, Look to Die Casting |
Presents data on heat sink materials comparisons and the strengths and weaknesses of heat sinks produced as stampings, extrusions, and die castings. Of special interest to designers less familiar with integral incorporation of heat sinks into a housing design or the potential of custom die cast sink designs View the PDF: Die Cast Heat Sink Can Be a Cost-Effective OEM Choice |
Eight precision components form the self-contained display and keypad plus probe connector unit for a new all-digital portable ultrasound system. A total component weight of 1.725 lbs. makes the unit lighter than a molded plastic design, with greater drop strength. Winner of a “Design Award of Excellence” from the International Magnesium Assn. View the PDF: Mg Die Cast Ultrasound Portable Workstation Housing |
Illustrated condensed overview of the basic contents of the die casting industry’s authoritative “Product Specification Standards for Die Castings” reference manual, as originally established in 1997. View the PDF: NADCA: Product Standards Manual Overview |
Facts on the material recycling infrastructure long in place for die cast metal parts and recyclability questions designers should ask in selecting materials and manufacturing processes for “green” component design. View the PDF: Designing for Servicing & Recyclability |
Designing for Servicing & Recyclability
New Mg die cast support structure for an advanced rear view automotive mirror is now being produced in a high-pressure hot-chamber mag die casting machine with trimming operations eliminated. Employing “in-die de-gating,” two-stage ejection technology, borrowed from miniature Zn die cast production, savings include eliminating the trim die build. (Includes photos) View the PDF: Mg IMA Process Technology Award for Auto Mirror |
Mg IMA Process Technology Award for Auto Mirror
When production runs for a machined component part increase, advanced net-shape die casting can offer substantial unit cost savings compared to part machining to specifications. Such cost reductions are being achieved for a wide variety of machined part applications in a range of alloys and part sizes. In the case of many small precision parts, the net-shape 4-slide miniature die casting process can be used to replace a brass machined part at no sacrifice in mechanical properties for significant savings at even low production volumes. This Tech Brief discusses the many advantages of machining-to-die casting conversions in addition to unit cost savings. View the PDF: Converting Machined Parts to Die Casting |
Converting Machined Parts to Die Casting
Two-Part Tech Brief: Part 1 outlines findings of recent Design News Study of design engineers: Salary gains, but with added duties. Part 2 presents a tailored listing of key initial resources in this DC2 Design Center for OEMs considering the die casting process, with direct download links to the described documents. Three DC2 OEM lists are presented, based on one’s design project role and process background. View the PDF: Design News Engrg Survey & Key DC2 OEM Resources |
Design News Engrg Survey & Key DC2 OEM Resources
Martin Hartlieb, President of Viami International Inc., describes the industry for aluminum alloys market in North America. This article studies trends and challenges from both various international resource centers. (OEM Tech Brief, No. 50) View the PDF: The Market for Aluminum Alloys in North America: Trends and Challenges |
6-page guide outlines 10 key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. These specific planning steps aid in integrating the realities of die cast manufacturing. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
10 Ways to Reduce the Costs of Die Cast Parts
Two Al and one Mg die casting Awards were won by CWM for a first-ever triple win for outstanding custom die castings in the annual North American Die Casting Association’s International Die Casting Competition.(Includes photos) View the PDF: 1st-ever Triple Winners in NADCA Die Casting Contest |
1st-ever Triple Winners in NADCA Die Casting Contest
The central component for a newly developed archery bow for serious young archers is a high-tech Al die casting produced to precision tolerance specifications and machined look and feel of a “hog out.” Delivered at the targeted market price, on a tightened time schedule to tie-in with promotional book and film release dates. NADCA Die Casting Award of Excellence winner. (Includes photos) View the PDF: Al Archery Bow NADCA Die Casting Award Winner |
Al Archery Bow NADCA Die Casting Award Winner
2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties, and nominal chemistry for its Al, Mg & Zn alloy capabilities. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
CWM Al, Mg & Zn Die Cast Production Specs
16-page, full-color comprehensive brochure on Chicago White Metal Casting capabilities in the most widely specified die casting alloys— Al, Mg & Zn. From design assistance through production, post-casting machining, surface finishing, and final product assembly. Detailed overview covers the experience, advanced technologies, and ISO 9001 & 14001 registered management systems that make CWM the cost-effective choice for net- and near-net-shape die cast parts. Includes case examples. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
CWM Comprehensive Die Casting Capabilities Brochure
Updated and expanded 16-page reference to the major design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among key design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. View the PDF: Design & Specification Guide for Custom Die Castings |
Design & Specification Guide for Custom Die Castings
Preplanning Guide to aid OEMs considering custom die cast part production and reviewing existing literature. Organizes selected industry and CWM design resources into a 7-step sequence for the planning process. The source of each die casting design and production bulletin, tech brief, guide, checklist, and reference manual is listed, with many available for Web downloading or forwarding by Email. Bulletin contains direct Web links to aid access or requests for all listed documents. View the PDF: Die Casting Design & Production Preplanning Guide |
The first motocross design produced on American soil in 20 years features many rule-breaking design innovations, such as its “sweet,” solid shifting clutch, made with two high-tech Al die castings. The Al hub has 35 gear teeth cast to zero draft. The crankshaft and engine cover are AZ91D hot-chamber mag die castings, providing strength and lightweight. View the PDF: Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft |
Designed as part of an advanced digital video processing and control system, Sony engineers specified “perfect parts” for their new professional video camera. CWM high-tech die casting was selected to produce 11 aluminum and hot-chamber magnesium housing components for the new camera. Superior as-cast surfaces were primary specifications. View the PDF: High-Tech Al & Mg for Advanced Video Imaging System |
High-Tech Al & Mg for Advanced Video Imaging System
Two intricate Al die castings are the heart of a vaporizer-regulator for propane and natural gas vehicles, winning an industry award for their casting excellence. Meeting important thermal and weight specs, the two castings that make up the unit have channel walls, and the spaces between them, that measure 0.040 in. (1.016 mm) thick. View the PDF: Intricate Al Die Cast Propane Vaporizer-Regulator |
Intricate Al Die Cast Propane Vaporizer-Regulator
This chart compares the material and physical properties for three popular die casting alloys: aluminum A380, magnesium AZ91D, Zinc #3, and ZA8. Several material properties such as tensile strength, impact, and yield strength can be compared between the three alloys. Physical properties such as density and conductivity can also be examined. View the PDF: Material / Physical Properties Comparison |
Material / Physical Properties Comparison
Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Aluminum Alloy Data |
NADCA Standards: Aluminum Alloy Data
Presentation to aid efficiency, functionality, and cost savings in the design and production of custom die castings. This narrated webinar focuses on helping effectively capitalize on today’s advanced die casting capabilities to improve performance and lower the costs of their custom components. 1 hour. |
Product Solutions Through Die Casting
Guide to developing optimum prototyping strategies for developing and testing component designs prior to final die casting die construction. Discusses prototyping alloys and processes, including new rapid prototyping technologies. View the PDF: Prototyping for Die Casting in All Alloys |
Prototyping for Die Casting in All Alloys
8-page condensed resource on evaluating finishing alternatives and optimizing component finishing decisions for Al, Mg, and Zn die cast products. Features a comparison table rating 32 surface coatings on relative cost, appearance, wear, and corrosion resistance; Presents recommended finishing for a range of typical die cast components. View the PDF: Quick Guide to Surface Finishing for Al, Mg & Zn Parts |
A wireless remote laser unit to aid pipelaying accuracy and efficiency is claimed to be the most powerful laser device of its kind allowed by law. The new model offers an Al die cast metal housing to meet extreme, rugged field conditions, difficult for plastic housings to survive. View the PDF: Rugged Al Die Cast Laser Housing Outperforms Plastic |
Presents the important factors that can affect the outcome of the final appearance of your die cast component when its surface finish is a critical issue. This narrated webinar will aid an understanding of the various finish options, and how their uses and limitations can make the difference between successful product development and costly results. 49 minutes. |
Brief overview of surface treatment systems for die cast part protection, decoration, and improving component performance, for all alloys: Al, Mg, Zn, and ZA. View the PDF: Surface Finishing for Die Casting Bulletin |
Surface Finishing for Die Casting Bulletin
This overview for OEM designers and specifiers is a refresher for those OEM product design engineers, buyers, and purchasing managers already familiar with die casting; and for those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
This white paper is a 6-page excerpt of an article that describes the current state of the United States Aluminum Casting Industry as it relates to Aluminum Die Casting. This article was written by The Folk Group. (Truncated Version) View the PDF: The U.S. Aluminum Casting Industry |
The U.S. Aluminum Casting Industry
This precision digital projector enclosure required high strength, rigidity, and low weight. The initial unit was produced as two magnesium Thixomold parts, assembled into one with seven bolts. CWM worked with the customer to redesign the enclosure as a single unit for Mg die casting production. The redesign resulted in a 40% final part cost reduction, a unit weight saving of 8%, and assured dimensional accuracy for improved projector focusing performance. View the PDF: Redesign Delivers 40% Unit Cost Saving, 8% Less Weight, Superior Performance |
Redesign Delivers 40% Unit Cost Saving, 8% Less Weight, Superior Performance
This white paper gives an overview of the benefits of Magnesium Die Casting in comparison to plastic and CWM’s response to magnesium. This paper also references case studies and other valuable resources. View the PDF: Die Casting’s Answer to Plastic: Magnesium |
Die Casting’s Answer to Plastic: Magnesium
Chicago White Metal explores magnesium die casting in this informative webinar. Reviews the unique properties of die casting with magnesium that can be employed in a new design or conversion from another process. The information presented in this webinar is for OEM product designers and engineers who want to understand how magnesium die casting can improve product performance and reduce costs. 50 minutes. |
Magnesium Die Casting: Solutions for Today’s Markets
6-page guide outlines 10 key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. These specific planning steps aid in integrating the realities of die cast manufacturing. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
Two Al and one Mg die casting Awards were won by CWM for a first-ever triple win for outstanding custom die castings in the annual North American Die Casting Association’s International Die Casting Competition.(Includes photos) View the PDF: 1st-ever Triple Winners in NADCA Die Casting Contest |
2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties, and nominal chemistry for its Al, Mg & Zn alloy capabilities. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
CWM Al, Mg & Zn Die Cast Production Specs
16-page, full-color comprehensive brochure on Chicago White Metal Casting capabilities in the most widely specified die casting alloys— Al, Mg & Zn. From design assistance through production, post-casting machining, surface finishing, and final product assembly. Detailed overview covers the experience, advanced technologies, and ISO 9001 & 14001 registered management systems that make CWM the cost-effective choice for net- and near-net-shape die cast parts. Includes case examples. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
CWM Comprehensive Die Casting Capabilities Brochure
Updated and expanded 16-page reference to the major design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among key design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. View the PDF: Design & Specification Guide for Custom Die Castings |
Preplanning Guide to aid OEMs considering custom die cast part production and reviewing existing literature. Organizes selected industry and CWM design resources into a 7-step sequence for the planning process. The source of each die casting design and production bulletin, tech brief, guide, checklist, and reference manual is listed, with many available for Web downloading or forwarding by Email. Bulletin contains direct Web links to aid access or requests for all listed documents. View the PDF: Die Casting Design & Production Preplanning Guide |
The first motocross design produced on American soil in 20 years features many rule-breaking design innovations, such as its “sweet,” solid shifting clutch, made with two high-tech Al die castings. The Al hub has 35 gear teeth cast to zero draft. The crankshaft and engine cover are AZ91D hot-chamber mag die castings, providing strength and lightweight. View the PDF: Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft |
Project managers for this satellite positioning system designed an Mg die cast enclosure as advanced as the new technology inside: ultra-rugged; lightweight for field use; waterproof; dustproof, with fail-safe EMI shielding. View the PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg |
Designed as part of an advanced digital video processing and control system, Sony engineers specified “perfect parts” for their new professional video camera. CWM high-tech die casting was selected to produce 11 aluminum and hot-chamber magnesium housing components for the new camera. Superior as-cast surfaces were primary specifications. View the PDF: High-Tech Al & Mg for Advanced Video Imaging System |
World leader in global positioning systems selected Mg die castings for the key housing components in their new optical surveying instrument. Machined parts were rejected as cost prohibitive; plastic would not provide the required stiffness for highly accurate readings. View the PDF: Key High-Tech Mg Parts for Optical Survey System |
Outlines EMI/RFI shielding requirements for electronic assemblies. Presents relationships between common measures of shielding, advantages of die castings in general, and mag die castings in particular, for electronic enclosure shielding. Prepared by Norsk Hydro Magnesium. View the PDF: Magnesium EMI Shielding Characteristics |
Magnesium EMI Shielding Characteristics
This chart compares the material and physical properties for three popular die casting alloys: aluminum A380, magnesium AZ91D, Zinc #3, and ZA8. Several material properties such as tensile strength, impact, and yield strength can be compared between the three alloys. Physical properties such as density and conductivity can also be examined. View the PDF: Material / Physical Properties Comparison |
Two Mg 12 x 17 in. precision die cast housing walls for an all-in-one multi-media desktop medical imager provide lightweight, multiple functions, and reduced part counts. Each high-tech hot-chamber mag die casting delivers 25 tight-toleranced features as-cast. View the PDF: Medical Imager Mg Multi-function Housing Walls |
First professional digital camera in a magnesium die cast housing, jointly developed by Kodak and Nikon. Mag, selected over the usual alternative of plastic encasing a stamped metal body or an Al casting, provides ruggedness, lightweight, and the quality feel of metal. View the PDF: Mg Die Cast Professional Digital Camera Case |
Mg Die Cast Professional Digital Camera Case
Eight precision components form the self-contained display and keypad plus probe connector unit for a new all-digital portable ultrasound system. A total component weight of 1.725 lbs. makes the unit lighter than a molded plastic design, with greater drop strength. Winner of a “Design Award of Excellence” from the International Magnesium Assn. View the PDF: Mg Die Cast Ultrasound Portable Workstation Housing |
Mg Die Cast Ultrasound Portable Workstation Housing
New Mg die cast support structure for an advanced rear view automotive mirror is now being produced in a high-pressure hot-chamber mag die casting machine with trimming operations eliminated. Employing “in-die de-gating,” two-stage ejection technology, borrowed from miniature Zn die cast production, savings include eliminating the trim die build. (Includes photos) View the PDF: Mg IMA Process Technology Award for Auto Mirror |
Mg IMA Process Technology Award for Auto Mirror
Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Magnesium Alloy Data |
NADCA Standards: Magnesium Alloy Data
NADCA updated comparison reviews die cast and plastic parts on material availability and recycling, material properties, design tolerances, and material costs. Examines the fact that plastic materials that offer higher strength than mag alloys have material costs that are at least four times greater than magnesium. View the PDF: NADCA: Comparison of Mag Die Casting & Plastic Parts |
Ruggedness, impact strength, and lightweight were key requirements for this handheld field unit for on-site analysis of voice and data. Specifications were met by this hot-chamber Mg die casting housing, which survives 4-foot drop tests to concrete. View the PDF: Only Mg Met Strength-Weight Specs for Voice/Data Unit |
Only Mg Met Strength-Weight Specs for Voice/Data Unit
Handheld fiber optic cable analyzer introduced in a high-tech magnesium die cast housing with elastomer overmolding. Innovative case, claimed to be the first overmolding of a complex die casting, offers improved performance over plastic at a 20% saving. View the PDF: Portable Die Cast Mg Case with Elastomer Overmolding |
Portable Die Cast Mg Case with Elastomer Overmolding
Presentation to aid efficiency, functionality, and cost savings in the design and production of custom die castings. This narrated webinar focuses on helping effectively capitalize on today’s advanced die casting capabilities to improve performance and lower the costs of their custom components. 1 hour. |
Product Solutions Through Die Casting
Guide to developing optimum prototyping strategies for developing and testing component designs prior to final die casting die construction. Discusses prototyping alloys and processes, including new rapid prototyping technologies. View the PDF: Prototyping for Die Casting in All Alloys |
Prototyping for Die Casting in All Alloys
8-page condensed resource on evaluating finishing alternatives and optimizing component finishing decisions for Al, Mg, and Zn die cast products. Features a comparison table rating 32 surface coatings on relative cost, appearance, wear and corrosion resistance; Presents recommended finishing for a range of typical die cast components. View the PDF: Quick Guide to Surface Finishing for Al, Mg & Zn Parts |
This advanced spotting scope, offering the sharpest, brightest viewing at distances greater than possible with premium binoculars, has impressive housing specifications: lightweight portability, absolute ruggedness, 100% waterproof construction— it is nitrogen filled and guaranteed for life. Its central housing is produced as a hot-chamber magnesium high-precision die casting, weighing just 8.0 oz. (226.8 gm) with thin-wall sections as narrow as 0.039 in. (1.0 mm). View the PDF: Rugged Mg Spotting Scope Die Casting Award |
A 2-page technical paper. It offers the facts to five ‘known’ misconceptions about magnesium die casting. It also discusses the unique properties that can be gained from die casting with magnesium. View the PDF: Still Believe These Five Magnesium Myths? |
Presents the important factors that can affect the outcome of the final appearance of your die cast component when its surface finish is a critical issue. This narrated webinar will aid an understanding of the various finish options, and how their uses and limitations can make the difference between successful product development and costly results. 49 minutes. |
Brief overview of surface treatment systems for die cast part protection, decoration, and improving component performance, for all alloys: Al, Mg, Zn, and ZA. View the PDF: Surface Finishing for Die Casting Bulletin |
This overview for OEM designers and specifiers is a refresher for those OEM product design engineers, buyers, and purchasing managers already familiar with die casting; and for those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a lightweight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands-down choice View the PDF: The Plastic vs Die Casting Process Decision |
The Plastic vs Die Casting Process Decision
This overview for OEM designers and specifiers is a refresher for those OEM product design engineers, buyers, and purchasing managers already familiar with die casting. For those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
Presents the facts on why multi-slide, miniature zinc die casting is the preferred choice for small precision components. It enables product designers to learn how this specialized die casting process can substantially reduce component costs and provide optimal precision to a new project design or a conversion from an existing process. |
6-page guide outlines ten key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. These specific planning steps aid in integrating the realities of die cast manufacturing. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties, and nominal chemistry for its Al, Mg & Zn alloy capabilities. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
Overview of Chicago White Metal Casting miniature 4-slide Zn 3, 5 & ZA-8 die cast part capabilities, with CWM specifications, alloy characteristics. CWM specializes in delivering miniature parts with any required post-casting finishing, ready for further assembly, including precision machining when net-shapes are not possible. View the PDF: CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data |
CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data
Updated and expanded 16-page reference to the initial design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among essential design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. View the PDF: Design & Specification Guide for Custom Die Castings |
Computer workstations from Silicon Graphics incorporated a zinc die cast rear cap frame, which combined important structural function with superior cosmetic appearance. The Zn die cast component, selected for its excellent strength, rigidity, EMI shielding characteristics, and part consolidation potential, was the first use by the company of a die casting in one of their workstation computers. View the PDF: Die Cast Zn for Key Computer Structural Component |
A value analysis of alternate production efficiencies for a low-volume CNC machined brass small component for a medical device resulted in a miniature zinc net-shape die cast replacement at a 500% unit cost saving. View the PDF: Replacement for Machined Brass at a 500% Savings |
Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. View the PDF: NADCA Design Manual: Intro & Content |
NADCA Design Manual: Intro & Content
This chart compares the material, and physical properties for three popular die casting alloys: aluminum A380, magnesium AZ91D, Zinc #3, and ZA8. Several material properties such as tensile strength, impact, and yield strength can be compared between the three alloys. Physical properties, such as density and conductivity, can also be examined. View the PDF: Material / Physical Properties Comparison |
Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Zinc & ZA Alloy Data |
Condensed overview for OEM product designers and engineers on Miniature Zinc & ZA-8 custom die casting for the cost-effective production of small, complex structural components. View the PDF: Primer on Miniature Zinc & ZA-8 Die Casting |
Primer on Miniature Zinc & ZA-8 Die Casting
Guide to developing optimum prototyping strategies for developing and testing component designs before final die casting die construction. This guide discusses prototyping alloys and processes, including new rapid prototyping technologies. View the PDF: Prototyping for Die Casting in All Alloys |
8-page condensed resource on evaluating finishing alternatives and optimizing component finishing decisions for Al, Mg, and Zn die cast products. Features a comparison table rating 32 surface coatings on relative cost, appearance, wear, and corrosion resistance; Presents recommended finishing for a range of typical die cast components. View the PDF: Quick Guide to Surface Finishing for Al, Mg & Zn Parts |
Brief overview of surface treatment systems for die cast part protection, decoration, and improving component performance, for all alloys: Al, Mg, Zn, and ZA. View the PDF: Surface Finishing for Die Casting Bulletin |
Surface Finishing for Die Casting Bulletin
Presentation to aid efficiency, functionality, and cost savings in the design and production of custom die castings. This narrated Webinar focuses on helping effectively capitalize on today’s advanced die casting capabilities to improve performance and lower the costs of their custom components. 1 hour. |
Presents the important factors that can affect the outcome of the final appearance of your die cast component when its surface finish is a critical issue. This narrated Webinar will aid an understanding of the various finish options and how their uses and limitations can make the difference between successful product development and costly results. 49 minutes. |
Surface Finishes for Die Casting
When production runs for a machined part increase, advanced net-shape die casting can offer substantial unit cost savings compared to part machining to specifications. Such cost reductions are being achieved for a wide variety of machined part applications in a range of alloys and part sizes. In the case of many small precision parts, the net-shape 4-slide miniature die casting process can be used to replace a brass machined part at no sacrifice in mechanical properties for significant savings at even low production volumes. This Tech Brief discusses the many advantages of machining-to-die casting conversions in addition to unit cost savings. View the PDF: Converting Machined Parts to Die Casting |
Converting Machined Parts to Die Casting
Condensed overview for OEM product designers and engineers on Miniature Zinc & ZA-8 custom die casting for the cost-effective production of small, complex structural components. View the PDF: Primer on Miniature Zinc & ZA-8 Die Casting |
Presents the facts on why multi-slide, miniature zinc die casting is the preferred choice for small precision components. It enables product designers to learn how this specialized die casting process can substantially reduce component costs and provide optimal precision to a new project design or a conversion from an existing process. |
The Miniature Zinc Die Casting Advantage
Overview of Chicago White Metal Casting miniature 4-slide Zn 3, 5 & ZA-8 die cast part capabilities, with CWM specifications, alloy characteristics. CWM specializes in delivering miniature parts with any required post-casting finishing, ready for further assembly, including precision machining when net-shapes are not possible. View the PDF: CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data |
CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data
A value analysis of alternate production efficiencies for a low-volume CNC machined brass small component for a medical device resulted in a miniature zinc net-shape die cast replacement at a 500% unit cost saving. View the PDF: Replacement for Machined Brass at a 500% Savings |
Overview of Chicago White Metal Casting miniature 4-slide Zn 3, 5 & ZA-8 die cast part capabilities, with CWM specifications, alloy characteristics. CWM specializes in delivering miniature parts with any required post-casting finishing, ready for further assembly, including precision machining when net-shapes are not possible. View the PDF: CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data |
An exercise in a step-by-step redesigning a part from a welded steel assembly to a die casting, applying recommended engineering principles, and the 1999 NADCA Product Standards for optimum die casting results. View the PDF: Design of a Bracket for Die Casting Production |
Design of a Bracket for Die Casting Production
This chart compares the material, and physical properties of three popular die casting alloys: aluminum A380, magnesium AZ91D, Zinc #3, and ZA8. Several material properties such as tensile strength, impact, and yield strength can be compared between the three alloys. Physical properties, such as density and conductivity, can also be examined. View the PDF: Material / Physical Properties Comparison |
Material / Physical Properties Comparison
This is a comprehensive resource on accepted contractual purchasing practices for purchasing die casting and related services based on established industry trade customs and prepared by the North American Die Casting Assn. It contains guidelines for developing proposals and contracts plus helpful checklists for printout on Tooling, Production, and Finishing Specifications. Covers defining quality requirements; die casting die and production tooling; transferred dies; die cast production part orders; purchased components; price adjustments; patent obligations; die casting warranties and product liability. View the PDF: NADCA Commercial Practices for Die Casting Buyers |
NADCA Commercial Practices for Die Casting Buyers
Al alloy selection, machining, and finishing data; chemical composition; material properties and die casting, and other characteristics. View the PDF: NADCA Standards: Aluminum Alloy Data |
NADCA Standards: Aluminum Alloy Data
Mg alloy selection, machining, and finishing data; chemical composition; material properties and die casting, and other characteristics. View the PDF: NADCA Standards: Magnesium Alloy Data |
NADCA Standards: Magnesium Alloy Data
Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting, and other characteristics. View the PDF: NADCA Standards: Zinc & ZA Alloy Data |
Presentation of “Standard” and “Precision” tolerances as outlined in the latest NADCA Product Standards Manual, plus outline of Coordinate Dimensioning vs. the advantages of the GD&T framework for specifying die cast parts. View the PDF: NADCA: Coordinate vs. Geometric Dimensioning Intro |
NADCA: Coordinate vs. Geometric Dimensioning Intro
Key factors in specifying the production and surface finishing of die cast parts, based on NADCA Product Standards Manual guidelines. Helps assure more transparent communication between OEM purchaser and die caster. (2015) View the PDF: NADCA: Die Cast Production & Finishing Checklists |
NADCA: Die Cast Production & Finishing Checklists
Illustrated condensed overview of the essential contents of the die casting industry’s authoritative “Product Specification Standards for Die Castings” reference manual, as initially established in 1997. View the PDF: NADCA: Product Standards Manual Overview |
NADCA: Product Standards Manual Overview
Aid to understanding die caster tooling requirements for optimum part production: Updated checklists for both new dies, and existing die casting dies to be transferred, based on NADCA Product Standards Manual guidelines. View the PDF: NADCA: Tooling Checklists for Die Casting Dies |
NADCA: Tooling Checklists for Die Casting Dies
Cross-reference chart for former superseded American Die Casting Institute (ADCI) and superseded North American Die Casting Assn. #401 (NADCA) Product Standards and current NADCA Product Standards. (2015) View the PDF: NADCA-ADCI Standards Cross-Reference Chart |
NADCA-ADCI Standards Cross-Reference Chart
Preplanning Guide to aid OEMs considering custom die cast part production and reviewing existing literature. Organizes selected industry and CWM design resources into a 7-step sequence for the planning process. The source of each die casting design and production bulletin, tech brief, guide, checklist, and reference manual is listed, with many available for Web downloading or forwarding by Email. Bulletin contains direct Web links to aid access or requests for all recorded documents. View the PDF: Die Casting Design & Production Preplanning Guide |
Die Casting Design & Production Preplanning Guide
16-page, full-color comprehensive brochure on Chicago White Metal Casting capabilities in the most widely specified die casting alloys— Al, Mg & Zn. From design assistance through production, post-casting machining, surface finishing, and final product assembly. Detailed overview covers the experience, advanced technologies, and ISO 9001 & 14001 registered management systems that make CWM the cost-effective choice for net- and near-net-shape die cast parts. Includes case examples. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
CWM Comprehensive Die Casting Capabilities Brochure
2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties, and nominal chemistry for its Al, Mg & Zn alloy capabilities. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
CWM Al, Mg & Zn Die Cast Production Specs
Describes how the use of this advanced in-house software technology, with simulated 3D computer metal-flow animations, can help assure 1st-shot success and die cast production repeatability. The benefits of further economical tooling design modifications can be revealed before tooling construction. View the PDF: How Magmasoft Process Simulation Lowers Costs |
How Magmasoft Process Simulation Lowers Costs
In-depth White Paper from the North American Die Casting Assn. details of how collaborative engineering between OEM engineers and custom die caster engineering can improve production efficiencies and reduce part costs. Discusses cost-saving opportunities for existing parts at tooling replacement or required product design revisions, as well as for clean sheet designs. View the PDF: NADCA Collaborative Engineering White Paper |
NADCA Collaborative Engineering White Paper
Comprehensive resource on accepted contractual purchasing practices for purchasing die casting and related services based on established industry trade customs. Prepared by the North American Die Casting Assn. It contains guidelines for developing proposals and contracts plus helpful checklists for printout on Tooling, Production and Finishing Specifications. Covers defining quality requirements; die casting die and production tooling; transferred dies; die cast production part orders; purchased components; price adjustments; patent obligations; die casting warranties and product liability. View the PDF: NADCA Commercial Practices for Die Casting Buyers |
NADCA Commercial Practices for Die Casting Buyers
Aid to understanding die caster tooling requirements for optimum part production: Updated checklists for both new dies, and existing die casting dies to be transferred, based on NADCA Product Standards Manual guidelines. View the PDF: NADCA: Tooling Checklists for Die Casting Dies |
NADCA: Tooling Checklists for Die Casting Dies
For users of machined parts looking for opportunities to reduce part costs while improving existing designs, with lower environmental impacts. Narrated webinar covers die cast conversion benefits and when such conversions are and are not advantageous. Tips on how best to make the transfer to an optimized die cast part. Covers conversion design considerations, alloys, and surface finishes— with case studies. 30 minutes. |
Machining to Die Casting: A Guide to Conversion
Presentation to aid efficiency, functionality, and cost savings in the design and production of custom die castings. This narrated Webinar focuses on helping effectively capitalize on today’s advanced die casting capabilities to improve performance and lower the costs of their custom components. 1 hour. |
This overview for OEM designers and specifiers is a refresher for those OEM product design engineers, buyers, and purchasing managers already familiar with die casting. For those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
Presents the facts on why multi-slide, miniature zinc die casting is the preferred choice for small precision components. It enables product designers to learn how this specialized die casting process can substantially reduce component costs and provide optimal precision to a new project design or a conversion from an existing process. |
6-page guide outlines ten key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. These specific planning steps aid in integrating the realities of die cast manufacturing. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
Presents data on heat sink materials comparisons and the strengths and weaknesses of heat sinks produced as stampings, extrusions, and die castings. Of particular interest to designers less familiar with integral incorporation of heat sinks into a housing design or the potential of custom die cast sink designs. View the PDF: Die Cast Heat Sink Can Be a Cost-Effective OEM Choice |
Die Cast Heat Sink Can Be a Cost-Effective OEM Choice
This in-depth White Paper from the North American Die Casting Assn. details of how collaborative engineering between OEM engineers and custom die caster engineering can result in improved production efficiencies and reduced part costs. The case study method is used to discuss cost-saving opportunities for existing parts at the point of tooling replacement or required product design revisions, as well as for clean sheet designs. View the PDF: NADCA Collaborative Engineering White Paper |
Updated and expanded 16-page reference to the superior design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among essential design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. View the PDF: Design & Specification Guide for Custom Die Castings |
Design & Specification Guide for Custom Die Castings
Learn more about the Die Cast Die with this document, taken from the NADCA Standards Book (2021). View the PDF: NADCA: Tooling for Die Casting |
NADCA: Tooling for Die Casting
For users of machined parts looking for opportunities to reduce part costs while improving existing designs, with lower environmental impacts. Narrated webinar covers die cast conversion benefits and when such conversions are and are not advantageous. Tips on how best to make the transfer to an optimized die cast part. Covers conversion design considerations, alloys, and surface finishes— with case studies. 30 minutes. |
This overview for OEM designers and specifiers is a refresher for those OEM product design engineers, buyers, and purchasing managers already familiar with die casting. For those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
6-page guide outlines ten key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. These specific planning steps aid in integrating the realities of die cast manufacturing. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
4-page condensed overview of Chicago White Metal Casting capabilities in Al, Mg, and Zn from front-end assistance, prototyping to part finishing, and assembly. Summarizes CWM’s experience, advanced technologies, and ISO 9001 & 14001 registered management systems. View the PDF: Overview of CWM Die Casting & Production Capabilities |
16-page, full-color comprehensive brochure on Chicago White Metal Casting capabilities in the most widely specified die casting alloys— Al, Mg & Zn. From design assistance through production, post-casting machining, surface finishing, and final product assembly. Detailed overview covers the experience, advanced technologies, and ISO 9001 & 14001 registered management systems that make CWM the cost-effective choice for net- and near-net-shape die cast parts. Includes case examples. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties, and nominal chemistry for its Al, Mg & Zn alloy capabilities. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
8-page, full-color brochure on CNC capabilities for machined prototypes in all metals, as well as plastics, for form, fit and functional testing; post-casting CNC machining; and low- to high-volume CNC part production, including screw machining. View the PDF: CWM CNC Machining Capabilities Brochure |
CWM CNC Machining Capabilities Brochure
This in-depth White Paper from the North American Die Casting Assn. details of how collaborative engineering between OEM engineers and custom die caster engineering can result in improved production efficiencies and reduced part costs. The case study method is used to discuss cost-saving opportunities for existing parts at the point of tooling replacement or required product design revisions, as well as for clean sheet designs. View the PDF: NADCA Collaborative Engineering White Paper |
Updated and expanded 16-page reference to the superior design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among essential design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. View the PDF: Design & Specification Guide for Custom Die Castings |
World leader in global positioning systems selected Mg die castings for the key housing components in their new optical surveying instrument. Machined parts were rejected as cost prohibitive; plastic would not provide the required stiffness for highly accurate readings. View the PDF: Key High-Tech Mg Parts for Optical Survey System |
A value analysis of alternate production efficiencies for a low-volume CNC machined brass small component for a medical device resulted in a miniature zinc net-shape die cast replacement at a 500% unit cost saving. View the PDF: Replacement for Machined Brass at a 500% Savings |
Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Aluminum Alloy Data |
Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Magnesium Alloy Data |
Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Zinc & ZA Alloy Data |
NADCA Standards: Zinc & ZA Alloy Data
This presentation will aid OEM product designers, engineers, and specifiers with valuable, practical guidelines for assuring sound design-for-manufacturing decisions before freezing their designs destined for die casting production. View the PDF: Leveraging DFM Before Design Commitment |
This overview for OEM designers and specifiers is a refresher for those OEM product design engineers, buyers and purchasing managers already familiar with die casting; and for those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
Presents the facts on why multi-slide, miniature zinc die casting is the preferred choice for small precision components. It enables product designers to learn how this specialized die casting process can substantially reduce component costs and provide optimal precision to a new project design or a conversion from an existing process. |
6-page guide outlines 10 key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. These specific planning steps aid in integrating the realities of die cast manufacturing. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
4-page condensed overview of Chicago White Metal Casting capabilities in Al, Mg, and Zn from front-end assistance, prototyping to part finishing, and assembly. Summarizes CWM’s experience, advanced technologies, and ISO 9001 & 14001 registered management systems. View the PDF: Overview of CWM Die Casting & Production Capabilities |
Overview of CWM Die Casting & Production Capabilities
Latest information on Trivalent chromium which is now a proven alternative to hexavalent chromium coatings and meets new U.S. and European Union environmental mandates. Economical, with a cosmetically pleasing finish, it offers high corrosion resistance for CWM Al, Mg & Zn die castings. View the PDF: EPA-Compliant Chromate for Al, Mg & Zn Parts |
EPA-Compliant Chromate for Al, Mg & Zn Parts
2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties, and nominal chemistry for its Al, Mg & Zn alloy capabilities. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
CWM Al, Mg & Zn Die Cast Production Specs
Comprehensive resource on accepted contractual purchasing practices for purchasing die casting and related services based on established industry trade customs. Prepared by the North American Die Casting Assn. It contains guidelines for developing proposals and contracts plus helpful checklists for printout on Tooling, Production and Finishing Specifications. Covers defining quality requirements; die casting die and production tooling; transferred dies; die cast production part orders; purchased components; price adjustments; patent obligations; die casting warranties and product liability. View the PDF: NADCA Commercial Practices for Die Casting Buyers |
Updated and expanded 16-page reference to the major design & specification steps that drive the cost and performance of components die cast in Al, Mg and Zn alloys. Among key design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. View the PDF: Design & Specification Guide for Custom Die Castings |
Design & Specification Guide for Custom Die Castings
Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Aluminum Alloy Data |
NADCA Standards: Aluminum Alloy Data
The central component for a newly developed archery bow for serious young archers is a high-tech Al die casting produced to precision tolerance specifications and machined look and feel of a “hog out.” Delivered at the targeted market price, on tightened time schedule to tie-in with promotional book and film release dates. NADCA Die Casting Award of Excellence winner. (Includes photos) View the PDF: Al Archery Bow NADCA Die Casting Award Winner |
Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Magnesium Alloy Data |
NADCA Standards: Magnesium Alloy Data
Computer workstations from Silicon Graphics incorporated a zinc die cast rear cap frame, which combined important structural function with superior cosmetic appearance. The Zn die cast component, selected for its excellent strength, rigidity, EMI shielding characteristics, and part consolidation potential, was the first use by the company of a die casting in one of their workstation computers. View the PDF: Die Cast Zn for Key Computer Structural Component |
Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Zinc & ZA Alloy Data |
Key factors in specifying the production and surface finishing of die cast parts, based on NADCA Product Standards Manual guidelines. Helps assure clearer communication between OEM purchaser and die caster. (2015) View the PDF: NADCA: Die Cast Production & Finishing Checklists |
NADCA: Die Cast Production & Finishing Checklists
Overmolding of a die cast enclosure allows product advantages beyond the soft-touch characteristics of elastomers. Tech Brief outlines design considerations that should be addressed by the design engineer planning a marriage of die casting and elastomer overmolding. View the PDF: Preliminary Guide to Overmolding of Die Cast Parts |
Preliminary Guide to Overmolding of Die Cast Parts
8-page condensed resource on evaluating finishing alternatives and optimizing component finishing decisions for Al, Mg, and Zn die cast products. Features a comparison table rating 32 surface coatings on relative cost, appearance, wear, and corrosion resistance; Presents recommended finishing for a range of typical die cast components. View the PDF: Quick Guide to Surface Finishing for Al, Mg & Zn Parts |
Brief overview of surface treatment systems for die cast part protection, decoration, and improving component performance, for all alloys: Al, Mg, Zn, and ZA. View the PDF: Surface Finishing for Die Casting Bulletin |
Step-by-step tutorial for a typical electronic enclosure design optimized for die casting takes the product designer through die casting design decisions applying recommended engineering principles appropriate to a range of similar design projects. Published by NADCA. View the PDF: Tutorial: Electronic Enclosure Design for Die Casting |
This presentation will aid OEM product designers, engineers, and specifiers with valuable, practical guidelines for assuring sound design-for-manufacturing decisions prior to freezing their designs destined for die casting production. View the PDF: Leveraging DFM Prior to Design Commitment |
Presents the important factors that can affect the outcome of the final appearance of your die cast component when its surface finish is a critical issue. This narrated webinar will aid an understanding of the various finish options, and how their uses and limitations can make the difference between successful product development and costly results. 49 minutes. |
6-page guide outlines 10 key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. These specific planning steps aid in integrating the realities of die cast manufacturing. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
New Mg die cast support structure for an advanced rear view automotive mirror is now being produced in a high-pressure hot-chamber mag die casting machine with trimming operations eliminated. Employing “in-die de-gating,” two-stage ejection technology, borrowed from miniature Zn die cast production, savings include eliminating the trim die build. (Includes photos) View the PDF: Mg IMA Process Technology Award for Auto Mirror |
Presents data on heat sink materials comparisons and the strengths and weaknesses of heat sinks produced as stampings, extrusions, and die castings. Of special interest to designers less familiar with integral incorporation of heat sinks into a housing design or the potential of custom die cast sink designs View the PDF: Die Cast Heat Sink Can Be a Cost-Effective OEM Choice |
Ruggedness, impact strength, and light weight were key requirements for this handheld field unit for on-site analysis of voice and data. Specifications were met by this hot-chamber Mg die casting housing, which survives 4-foot drop tests to concrete. View the PDF: Only Mg Met Strength-Weight Specs for Voice/Data Unit |
2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties, and nominal chemistry for its Al, Mg & Zn alloy capabilities. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
Handheld fiber optic cable analyzer introduced in a high-tech magnesium die cast housing with elastomer overmolding. Innovative case, claimed to be the first overmolding of a complex die casting, offers improved performance over plastic at a 20% saving. View the PDF: Portable Die Cast Mg Case with Elastomer Overmolding |
Overview of Chicago White Metal Casting miniature 4-slide Zn 3, 5 & ZA-8 die cast part capabilities, with CWM specifications, alloy characteristics. CWM specializes in delivering miniature parts with any required post-casting finishing, ready for further assembly, including precision machining when net-shapes are not possible. View the PDF: CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data |
CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data
A value analysis of alternate production efficiencies for a low-volume CNC machined brass small component for a medical device resulted in a miniature zinc net-shape die cast replacement at a 500% unit cost saving. View the PDF: Replacement for Machined Brass at a 500% Savings |
When production runs for a machined component part increase, advanced net-shape die casting can offer substantial unit cost savings compared to part machining to specifications. Such cost reductions are being achieved for a wide variety of machined part applications in a range of alloys and part sizes. In the case of many small precision parts, the net-shape 4-slide miniature die casting process can be used to replace a brass machined part at no sacrifice in mechanical properties for significant savings at even low production volumes. This Tech Brief discusses the many advantages of machining-to-die casting conversions in addition to unit cost savings. View the PDF: Converting Machined Parts to Die Casting |
This in-depth White Paper from the North American Die Casting Assn. details of how collaborative engineering between OEM engineers and custom die caster engineering can result in improved production efficiencies and reduced part costs. The case study method is used to discuss cost-saving opportunities for existing parts at the point of tooling replacement or required product design revisions, as well as for clean sheet designs. View the PDF: NADCA Collaborative Engineering White Paper |
Chicago White Metal explores magnesium die casting in this informative webinar. Reviews the unique properties of die casting with magnesium that can be employed in a new design or conversion from another process. The information presented in this webinar is for OEM product designers and engineers who want to understand how magnesium die casting can improve product performance and reduce costs. 50 minutes. |
Using the “functional build” methodology in part production, widely embraced by Japanese engineers, many North American OEMs are now making higher performing end-product assemblies at lower costs with greater customer satisfaction. View the PDF: Functional-Build Approach to Lower Production Costs |
Functional-Build Approach to Lower Production Costs
Updated and expanded 16-page reference to the major design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among key design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. View the PDF: Design & Specification Guide for Custom Die Castings |
Summary of detailed findings of OEM offshore sourcing based on research by the North American Die Casting Assn. Drawn by the promise of low prices, many North American OEM buyers and product specifiers who have engaged in offshore sourcing of die castings have learned hard lessons: the transoceanic pipeline can be very long and filled with unforeseen—and costly—outcomes. Most OEMs who have purchased die castings overseas have at least one revealing story to relate. View the PDF: Hidden Costs of Sourcing Die Castings Offshore |
Hidden Costs of Sourcing Die Castings Offshore
Two Al and one Mg die casting Awards were won by CWM for a first-ever triple win for outstanding custom die castings in the annual North American Die Casting Association’s International Die Casting Competition. (Includes photos) View the PDF: 1st-ever Triple Winners in NADCA Die Casting Contest |
1st-ever Triple Winners in NADCA Die Casting Contest
Describes how the use of this advanced in-house software technology, with simulated 3D computer metal-flow animations, can help assure 1st-shot success and die cast production repeatability. The benefits of further economical tooling design modifications can be clearly revealed prior to tooling construction. View the PDF: How Magmasoft Process Simulation Lowers Costs |
Computer workstations from Silicon Graphics incorporated a zinc die cast rear cap frame, which combined important structural function with superior cosmetic appearance. The Zn die cast component, selected for its excellent strength, rigidity, EMI shielding characteristics, and part consolidation potential, was the first use by the company of a die casting in one of their workstation computers. View the PDF: Die Cast Zn for Key Computer Structural Component |
In-depth White Paper from the North American Die Casting Assn. details of how collaborative engineering between OEM engineers and custom die caster engineering can improve production efficiencies and reduce part costs. Discusses cost-saving opportunities for existing parts at tooling replacement or required product design revisions, as well as for clean sheet designs. View the PDF: NADCA Collaborative Engineering White Paper |
First motocross design produced on American soil in 20 years features many rule-breaking design innovations, such as its “sweet,” solid shifting clutch, made with two high-tech Al die castings. The Al hub has 35 gear teeth cast to zero draft. The crankshaft and engine cover are AZ91D hot-chamber mag die castings, providing strength and lightweight. View the PDF: Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft |
Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft
Die castings offer exceptional design freedom while at the same time achieving excellent mechanical properties for a product component. Selected features should be designed to enhance casting quality and avoid unnecessary casting costs. This article offers details on key points to consider in optimizing the cost-performance equation for a die cast part. View the PDF: NADCA: Pointers for Designing Die Castings |
Project managers for this satellite positioning system designed a Mg die cast enclosure as advanced as the new technology inside: ultra-rugged; lightweight for field use; waterproof; dustproof, with fail-safe EMI shielding. View the PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg |
Charles Fishman, award-winning investigative and magazine journalist writing in the Atlantic magazine, explores what he calls a startling, sustainable, just-getting-started return of industry to the United States. After years of offshore production, U.S. companies are moving much of their far-flung manufacturing operations back home. General Electric is an early example, but it is not alone. Whirlpool, from China to Ohio; Otis, from Mexico to South Carolina; even Wham-O, from China to California. This Tech Brief is a condensation of his recent in-depth article with reasons for these major production shifts that he labels “The Insourcing Boom.” View the PDF: The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S |
The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S
Designed as part of an advanced digital video processing and control system, Sony engineers specified “perfect parts” for their new professional video camera. CWM high-tech die casting was selected to produce 11 aluminum and hot-chamber magnesium housing components for the new camera. Superior as-cast surfaces were primary specifications. View the PDF: High-Tech Al & Mg for Advanced Video Imaging System |
August 2010 article reports on plans for important production moving back from far-flung locations such as China; 400 jobs in the case of GE, 2000 jobs for components provided by suppliers for Ford. For the complete story and the reasons reported for this “reshoring” movement, View the PDF: USA Today: Manufacturing Heading Back to USA? |
USA Today: Manufacturing Heading Back to USA?
Two intricate Al die castings are the heart of a vaporizer-regulator for propane and natural gas vehicles, winning an industry award for their casting excellence. Meeting important thermal and weight specs, the two castings that make up the unit have channel walls, and the spaces between them, that measure 0.040 in. (1.016 mm) thick. View the PDF: Intricate Al Die Cast Propane Vaporizer-Regulator |
For users of machined parts looking for opportunities to reduce part costs while improving existing designs, with lower environmental impacts. Narrated webinar covers die cast conversion benefits and when such conversions are and are not advantageous. Tips on how best to make the transfer to an optimized die cast part. Covers conversion design considerations, alloys and surface finishes— with case studies. 30 minutes. |
World leader in global positioning systems selected Mg die castings for the key housing components in their new optical surveying instrument. Machined parts were rejected as cost prohibitive; plastic would not provide the required stiffness for highly accurate readings. View the PDF: Key High-Tech Mg Parts for Optical Survey System |
Presentation to aid efficiency, functionality, and cost savings in the design and production of custom die castings. This narrated webinar focuses on helping effectively capitalize on today’s advanced die casting capabilities to improve performance and lower the costs of their custom components. 1 hour. |
Two Mg 12 x 17 in. precision die cast housing walls for an all-in-one multi-media desktop medical imager provide lightweight, multiple functions and reduced part counts. Each high-tech hot-chamber mag die casting delivers 25 tight-toleranced features as-cast. View the PDF: Medical Imager Mg Multi-function Housing Walls |
Medical Imager Mg Multi-function Housing Walls
Presents the important factors that can affect the outcome of the final appearance of your die cast component when its surface finish is a critical issue. This narrated webinar will aid an understanding of the various finish options, and how their uses and limitations can make the difference between successful product development and costly results. 49 minutes. |
First professional digital camera in a magnesium die cast housing, jointly developed by Kodak and Nikon. Mag, selected over the usual alternative of plastic encasing a stamped metal body or an Al casting, provides ruggedness, lightweight, and the quality feel of metal. View the PDF: Mg Die Cast Professional Digital Camera Case |
Presents the facts on why multi-slide, miniature zinc die casting is the preferred choice for small precision components. It enables product designers to learn how this specialized die casting process can substantially reduce component costs and provide optimal precision to a new project design or a conversion from an existing process. |
The Miniature Zinc Die Casting Advantage
Eight precision components form the self-contained display and keypad plus probe connector unit for a new all-digital portable ultrasound system. A total component weight of 1.725 lbs. makes the unit lighter than a molded plastic design, with greater drop strength. Winner of a “Design Award of Excellence” from the International Magnesium Assn. View the PDF: Mg Die Cast Ultrasound Portable Workstation Housing |
This precision digital projector enclosure required high strength, rigidity, and low weight. The initial unit was produced as two magnesium Thixomold parts, assembled into one with seven bolts. CWM worked with the customer to redesign the enclosure as a single unit for Mg die casting production. The redesign resulted in a 40% final part cost reduction, a unit weight saving of 8%, and assured dimensional accuracy for improved projector focusing performance. View the PDF: Redesign Delivers 40% Unit Cost Saving, 8% Less Weight, Superior Performance |
6-page guide outlines 10 key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. These specific planning steps aid in integrating the realities of die cast manufacturing. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
When production runs for a machined component part increase, advanced net-shape die casting can offer substantial unit cost savings compared to part machining to specifications. Such cost reductions are being achieved for a wide variety of machined part applications in a range of alloys and part sizes. In the case of many small precision parts, the net-shape 4-slide miniature die casting process can be used to replace a brass machined part at no sacrifice in mechanical properties for significant savings at even low production volumes. This Tech Brief discusses the many advantages of machining-to-die casting conversions in addition to unit cost savings. View the PDF: Converting Machined Parts to Die Casting |
An exercise in a step-by-step redesigning a part from a welded steel assembly to a die casting, applying recommended engineering principles, and the 1999 NADCA Product Standards for optimum die casting results. View the PDF: Design of a Bracket for Die Casting Production |
Presents data on heat sink materials comparisons and the strengths and weaknesses of heat sinks produced as stampings, extrusions, and die castings. Of special interest to designers less familiar with integral incorporation of heat sinks into a housing design or the potential of custom die cast sink designs View the PDF: Die Cast Heat Sink Can Be a Cost-Effective OEM Choice |
Introductory overview and guide to optimum materials and alternate process selection. It contains a physical and mechanical materials properties comparison chart for the most widely used Al, Mg & Zn die casting alloys. View the PDF: Evaluating Materials & Processes |
This presentation will aid OEM product designers, engineers, and specifiers with valuable, practical guidelines for assuring sound design-for-manufacturing decisions prior to freezing their designs destined for die casting production. View the PDF: Leveraging DFM Prior to Design Commitment |
For users of machined parts looking for opportunities to reduce part costs while improving existing designs, with lower environmental impacts. Narrated webinar covers die cast conversion benefits and when such conversions are and are not advantageous. Tips on how best to make the transfer to an optimized die cast part. Covers conversion design considerations, alloys, and surface finishes— with case studies. 30 minutes. |
Chicago White Metal explores magnesium die casting in this informative webinar. Reviews the unique properties of die casting with magnesium that can be employed in a new design or conversion from another process. The information presented in this webinar is for OEM product designers and engineers who want to understand how magnesium die casting can improve product performance and reduce costs. 50 minutes. |
Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. View the PDF: NADCA Design Manual: Intro & Content |
NADCA updated comparison reviews die cast and plastic parts on material availability and recycling, material properties, design tolerances, and material costs. Examines the fact that plastic materials that offer higher strength than mag alloys have material costs that are at least four times greater than magnesium. View the PDF: NADCA: Comparison of Mag Die Casting & Plastic Parts |
Handheld fiber optic cable analyzer introduced in a high-tech magnesium die cast housing with elastomer overmolding. Innovative case, claimed to be the first overmolding of a complex die casting, offers improved performance over plastic at a 20% saving. View the PDF: Portable Die Cast Mg Case with Elastomer Overmolding |
Condensed overview for OEM product designers and engineers on Miniature Zinc & ZA-8 custom die casting for the cost-effective production of small, complex structural components. View the PDF: Primer on Miniature Zinc & ZA-8 Die Casting |
Presentation to aid efficiency, functionality, and cost savings in the design and production of custom die castings. This narrated webinar focuses on helping effectively capitalize on today’s advanced die casting capabilities to improve performance and lower the costs of their custom components. 1 hour. |
A wireless remote laser unit to aid pipelaying accuracy and efficiency is claimed to be the most powerful laser device of its kind allowed by law. The new model offers an Al die cast metal housing to meet extreme, rugged field conditions, difficult for plastic housings to survive. View the PDF: Rugged Al Die Cast Laser Housing Outperforms Plastic |
Presents the facts on why multi-slide, miniature zinc die casting is the preferred choice for small precision components. It enables product designers to learn how this specialized die casting process can substantially reduce component costs and provide optimal precision to a new project design or a conversion from an existing process. |
If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a lightweight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands-down choice View the PDF: The Plastic vs Die Casting Process Decision |
Step-by-step tutorial for a typical electronic enclosure design optimized for die casting takes the product designer through die casting design decisions applying recommended engineering principles appropriate to a range of similar design projects. Published by NADCA. View the PDF: Tutorial: Electronic Enclosure Design for Die Casting |
Step-by-step tutorial for a redesigned bracket design optimized for die casting takes the product designer through die casting design and redesign decisions applying recommended engineering principles appropriate to a range of similar redesign projects. Published by NADCA. View the PDF: Tutorial: Redesigning a Steel Bracket for Die Casting |
Guide to developing optimum prototyping strategies for developing and testing component designs prior to final die casting die construction. Discusses prototyping alloys and processes, including new rapid prototyping technologies. View the PDF: Prototyping for Die Casting in All Alloys |
This presentation will aid OEM product designers, engineers, and specifiers with valuable, practical guidelines for assuring sound design-for-manufacturing decisions prior to freezing their designs destined for die casting production. View the PDF: Leveraging DFM Prior to Design Commitment |
For users of machined parts looking for opportunities to reduce part costs while improving existing designs, with lower environmental impacts. Narrated webinar covers die cast conversion benefits and when such conversions are and are not advantageous. Tips on how best to make the transfer to an optimized die cast part. Covers conversion design considerations, alloys, and surface finishes— with case studies. 30 minutes. |
4-page condensed overview of Chicago White Metal Casting capabilities in Al, Mg, and Zn from front-end assistance, prototyping to part finishing, and assembly. Summarizes CWM’s experience, advanced technologies, and ISO 9001 & 14001 registered management systems. View the PDF: Overview of CWM Die Casting & Production Capabilities |
16-page, full-color comprehensive brochure on Chicago White Metal Casting capabilities in the most widely specified die casting alloys— Al, Mg & Zn. From design assistance through production, post-casting machining, surface finishing, and final product assembly. Detailed overview covers the experience, advanced technologies, and ISO 9001 & 14001 registered management systems that make CWM the cost-effective choice for net- and near-net-shape die cast parts. Includes case examples. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties, and nominal chemistry for its Al, Mg & Zn alloy capabilities. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
Updated and expanded 16-page reference to the major design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among key design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. View the PDF: Design & Specification Guide for Custom Die Castings |
Latest information on Trivalent chromium which is now a proven alternative to hexavalent chromium coatings and meets new U.S. and European Union environmental mandates. Economical, with a cosmetically pleasing finish, it offers high corrosion resistance for CWM Al, Mg & Zn die castings. View the PDF: EPA-Compliant Chromate for Al, Mg & Zn Parts |
A concise outline of the specific facts regarding how die casting manufacturing efficiency contributes to ecological sustainability: All die casting metals can be recycled and reused with no loss in material properties, resulting in the vast majority of die castings made with post-consumer metals which, in addition, require far less energy to reprocess than virgin materials. In the production of non-ferrous metal castings, die casting is the most energy-efficient casting process, with reusable molds and very high production rates resulting in highly-efficient energy usage. The carbon footprint of the die casting industry is among the lowest among producers of net- or near-net shape products and component parts—far less than that of plastic injection moldings. View the PDF: NADCA: For Efficient Manufacturing, Look to Die Casting |
If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a lightweight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands-down choice View the PDF: The Plastic vs Die Casting Process Decision |
Facts on the material recycling infrastructure long in place for die cast metal parts and recyclability questions designers should ask in selecting materials and manufacturing processes for “green” component design. View the PDF: Designing for Servicing & Recyclability |
Two Al and one Mg die casting Awards were won by CWM for a first-ever triple win for outstanding custom die castings in the annual North American Die Casting Association’s International Die Casting Competition.(Includes photos) View the PDF: 1st-ever Triple Winners in NADCA Die Casting Contest |
First professional digital camera in a magnesium die cast housing, jointly developed by Kodak and Nikon. Mag, selected over the usual alternative of plastic encasing a stamped metal body or an Al casting, provides ruggedness, lightweight, and the quality feel of metal. View the PDF: Mg Die Cast Professional Digital Camera Case |
Mg Die Cast Professional Digital Camera Case
Describes how the use of this advanced in-house software technology, with simulated 3D computer metal-flow animations, can help assure 1st-shot success and die cast production repeatability. The benefits of further economical tooling design modifications can be clearly revealed prior to tooling construction. View the PDF: How Magmasoft Process Simulation Lowers Costs |
How Magmasoft Process Simulation Lowers Costs
Outlines EMI/RFI shielding requirements for electronic assemblies. Presents relationships between common measures of shielding, advantages of die castings in general, and mag die castings in particular, for electronic enclosure shielding. Prepared by Norsk Hydro Magnesium. View the PDF: Magnesium EMI Shielding Characteristics |
Magnesium EMI Shielding Characteristics
NADCA updated comparison reviews die cast and plastic parts on material availability and recycling, material properties, design tolerances, and material costs. Examines the fact that plastic materials that offer higher strength than mag alloys have material costs that are at least four times greater than magnesium. View the PDF: NADCA: Comparison of Mag Die Casting & Plastic Parts |
Presentation to aid efficiency, functionality, and cost savings in the design and production of custom die castings. This narrated webinar focuses on helping effectively capitalize on today’s advanced die casting capabilities to improve performance and lower the costs of their custom components. 1 hour. |
Preplanning Guide to aid OEMs considering custom die cast part production and reviewing existing literature. Organizes selected industry and CWM design resources into a 7-step sequence for the planning process. The source of each die casting design and production bulletin, tech brief, guide, checklist, and reference manual is listed, with many available for Web downloading or forwarding by Email. Bulletin contains direct Web links to aid access or requests for all listed documents. View the PDF: Die Casting Design & Production Preplanning Guide |
4-page condensed overview of Chicago White Metal Casting capabilities in Al, Mg, and Zn from front-end assistance, prototyping to part finishing, and assembly. Summarizes CWM’s experience, advanced technologies, and ISO 9001 & 14001 registered management systems. View the PDF: Overview of CWM Die Casting & Production Capabilities |
16-page, full-color comprehensive brochure on Chicago White Metal Casting capabilities in the most widely specified die casting alloys— Al, Mg & Zn. From design assistance through production, post-casting machining, surface finishing, and final product assembly. Detailed overview covers the experience, advanced technologies, and ISO 9001 & 14001 registered management systems that make CWM the cost-effective choice for net- and near-net-shape die cast parts. Includes case examples. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties, and nominal chemistry for its Al, Mg & Zn alloy capabilities. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
Comprehensive resource on accepted contractual purchasing practices for purchasing die casting and related services based on established industry trade customs. Prepared by the North American Die Casting Assn. It contains guidelines for developing proposals and contracts plus helpful checklists for printout on Tooling, Production and Finishing Specifications. Covers defining quality requirements; die casting die and production tooling; transferred dies; die cast production part orders; purchased components; price adjustments; patent obligations; die casting warranties and product liability. View the PDF: NADCA Commercial Practices for Die Casting Buyers |
Updated and expanded 16-page reference to the superior design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among essential design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. View the PDF: Design & Specification Guide for Custom Die Castings |
NADCA updated comparison reviews die cast and plastic parts on material availability and recycling, material properties, design tolerances, and material costs. Examines the fact that plastic materials that offer higher strength than mag alloys have material costs that are at least four times greater than magnesium. View the PDF: NADCA: Comparison of Mag Die Casting & Plastic Parts |
Key factors in specifying the production and surface finishing of die cast parts, based on NADCA Product Standards Manual guidelines. Helps assure more transparent communication between OEM purchaser and die caster. (2015) View the PDF: NADCA: Die Cast Production & Finishing Checklists |
A concise outline of the specific facts regarding how die casting manufacturing efficiency contributes to ecological sustainability: All die casting metals can be recycled and reused with no loss in material properties, resulting in the vast majority of die castings made with post-consumer metals which, also, require far less energy to reprocess than virgin materials. In the production of non-ferrous metal castings, die casting is the most energy-efficient casting process, with reusable molds and very high production rates resulting in highly-efficient energy usage. The carbon footprint of the die casting industry is among the lowest among producers of net- or near-net shape products and component parts—far less than that of plastic injection moldings. View the PDF: NADCA: For Efficient Manufacturing, Look to Die Casting |
Charles Fishman, award-winning investigative and magazine journalist, writing in the Atlantic magazine, explores what he calls a startling, sustainable, just-getting-started return of industry to the United States. After years of offshore production, U.S. companies are moving much of their far-flung manufacturing operations back home. General Electric is an early example, but it is not alone. Whirlpool, from China to Ohio; Otis, from Mexico to South Carolina; even Wham-O, from China to California. This Tech Brief is a condensation of his recent in-depth article with reasons for these major production shifts that he labels “The Insourcing Boom.” View the PDF: The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S |
August 2010 article reports on plans for significant production moving back from far-flung locations such as China; 400 jobs in the case of GE, 2000 jobs for components provided by suppliers for Ford. For the complete story and the reasons reported for this “reshoring” movement, View the PDF: USA Today: Manufacturing Heading Back to USA? |
This presentation will aid OEM product designers, engineers, and specifiers with valuable, practical guidelines for assuring sound design-for-manufacturing decisions before freezing their designs destined for die casting production. View the PDF: Leveraging DFM Prior to Design Commitment |
For users of machined parts looking for opportunities to reduce part costs while improving existing designs, with lower environmental impacts. Narrated webinar covers die cast conversion benefits and when such conversions are and are not advantageous. Tips on how best to make the transfer to an optimized die cast part. Covers conversion design considerations, alloys, and surface finishes— with case studies. 30 minutes. |
Paul Midler, with a background in Chinese studies and history– and hands-on experience working for years in China with Chinese supplier manufacturers– has written a valuable new book, “Poorly Made in China,” Any North American OEM considering offshore sourcing will want to be familiar with the information this original businessman-author documents. View the PDF: Book Review: “Poorly Made in China” |
Book Review: “Poorly Made in China”
Presentation to aid efficiency, functionality, and cost savings in the design and production of custom die castings. This narrated Webinar focuses on helping effectively capitalize on today’s advanced die casting capabilities to improve performance and lower the costs of their custom components. 1 hour. |
Two-Part Tech Brief: Part 1 outlines findings of recent Design News Study of design engineers: Salary gains, but with added duties. Part 2 presents a tailored listing of essential initial resources in this DC2 Design Center for OEMs considering the die casting process, with direct download links to the described documents. Three DC2 OEM lists are presented, based on one’s design project role and process background. View the PDF: Design News Engrg Survey & Key DC2 OEM Resources |
Presents the important factors that can affect the outcome of the final appearance of your die cast component when its surface finish is a critical issue. This narrated Webinar will aid an understanding of the various finish options and how their uses and limitations can make the difference between successful product development and costly results. 49 minutes. |
Certain design and production myths regarding die casting may be crippling material and manufacturing decision making. This discussion, by CWM’s V.P. of Engineering, takes a look at today’s die casting design realities. View the PDF: Die Cast Design Myths Can Cripple Optimum Decisions |
Die Cast Design Myths Can Cripple Optimum Decisions
This overview for OEM designers and specifiers is a refresher for those OEM product design engineers, buyers, and purchasing managers already familiar with die casting. For those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
A comprehensive one-page resource compilation for OEM buyers to aid in reviewing die cast custom part specifications for production and guiding optimum sourcing decisions. The location of each resource, bulletin, tech brief, guide, and checklist is listed, all either directly viewable on the Internet or available for immediate Web downloading. View the PDF: Die Casting Spec & Sourcing Aids for OEM Buyers |
Presents the facts on why multi-slide, miniature zinc die casting is the preferred choice for small precision components. It enables product designers to learn how this specialized die casting process can substantially reduce component costs and provide optimal precision to a new project design or a conversion from an existing process. |
Summary of detailed findings of OEM offshore sourcing based on research by the North American Die Casting Assn. Drawn by the promise of low prices, many North American OEM buyers and product specifiers who have engaged in offshore sourcing of die castings have learned hard lessons: the transoceanic pipeline can be very long and filled with unforeseen—and costly—outcomes. Most OEMs who have purchased die castings overseas have at least one revealing story to relate. View the PDF: Hidden Costs of Sourcing Die Castings Offshore |
6-page guide outlines ten key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. These specific planning steps aid in integrating the realities of die cast manufacturing. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
This 10-point OEM checklist can be a helpful guide to making the optimum supplier decision for successful results in producing a new housing or component as a custom die casting in aluminum, magnesium, or zinc. View the PDF: How to Select the Best Custom Die Caster |
How to Select the Best Custom Die Caster
Preplanning Guide to aid OEMs considering custom die cast part production and reviewing existing literature. Organizes selected industry and CWM design resources into a 7-step sequence for the planning process. The source of each die casting design and production bulletin, tech brief, guide, checklist, and reference manual is listed, with many available for Web downloading or forwarding by Email. Announcement contains direct Web links to aid access or requests for all recorded documents. View the PDF: Die Casting Design & Production Preplanning Guide |
Outlines EMI/RFI shielding requirements for electronic assemblies. Presents relationships between standard measures of shielding, advantages of die castings in general, and mag die castings in particular, for electronic enclosure shielding. Norsk Hydro Magnesium prepares them. View the PDF: Magnesium EMI Shielding Characteristics |
2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties, and nominal chemistry for its Al, Mg & Zn alloy capabilities. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
In-depth White Paper from the North American Die Casting Assn. details of how collaborative engineering between OEM engineers and custom die caster engineering can improve production efficiencies and reduce part costs. Discusses cost-saving opportunities for existing parts at tooling replacement or required product design revisions, as well as for clean sheet designs. View the PDF: NADCA Collaborative Engineering White Paper |
Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Aluminum Alloy Data |
Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Magnesium Alloy Data |
Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Zinc & ZA Alloy Data |
More densely-packed housings, faster processing speeds, and new EMI regulations call for changes in electronic housing designs. This paper frames the EMI shielding challenge, the importance of attention to shielding concerns well before the prototyping stage, and outlines the pros and cons of shielding alternatives in metal and plastic housings. View the PDF: Superior EMI Shielding with Die Cast Housings |
Superior EMI Shielding with Die Cast Housings
If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a lightweight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands-down choice View the PDF: The Plastic vs Die Casting Process Decision |
Step-by-step tutorial for a typical electronic enclosure design optimized for die casting takes the product designer through die casting design decisions applying recommended engineering principles appropriate to a range of similar design projects. Published by NADCA. View the PDF: Tutorial: Electronic Enclosure Design for Die Casting |
Computer workstations from Silicon Graphics incorporated a zinc die cast rear cap frame, which combined important structural function with superior cosmetic appearance. The Zn die cast component, selected for its excellent strength, rigidity, EMI shielding characteristics, and part consolidation potential, was the first use by the company of a die casting in one of their workstation computers. View the PDF: Die Cast Zn for Key Computer Structural Component |
Project managers for this satellite positioning system designed a Mg die cast enclosure as advanced as the new technology inside: ultra-rugged; lightweight for field use; waterproof; dustproof, with fail-safe EMI shielding. View the PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg |
This advanced spotting scope, offering the sharpest, brightest viewing at distances greater than possible with premium binoculars, has impressive housing specifications: lightweight portability, absolute ruggedness, 100% waterproof construction— it is nitrogen filled and guaranteed for life. Its central housing is produced as a hot-chamber magnesium high-precision die casting, weighing just 8.0 oz. (226.8 gm) with thin-wall sections as narrow as 0.039 in. (1.0 mm). View the PDF: Rugged Mg Spotting Scope Die Casting Award |
Paul Midler, with a background in Chinese studies and history– and hands-on experience working for years in China with Chinese supplier manufacturers– has written a valuable new book, “Poorly Made in China,” Any North American OEM considering offshore sourcing will want to be familiar with the information this original businessman-author documents. View the PDF: Book Review: “Poorly Made in China” |
Summary of detailed findings of OEM offshore sourcing based on research by the North American Die Casting Assn. Drawn by the promise of low prices, many North American OEM buyers and product specifiers who have engaged in offshore sourcing of die castings have learned hard lessons: the transoceanic pipeline can be very long and filled with unforeseen—and costly—outcomes. Most OEMs who have purchased die castings overseas have at least one revealing story to relate. View the PDF: Hidden Costs of Sourcing Die Castings Offshore |
Charles Fishman, award-winning investigative and magazine journalist, writing in the Atlantic magazine, explores what he calls a startling, sustainable, just-getting-started return of industry to the United States. After years of offshore production, U.S. companies are moving much of their far-flung manufacturing operations back home. General Electric is an early example, but it is not alone. Whirlpool, from China to Ohio; Otis, from Mexico to South Carolina; even Wham-O, from China to California. This Tech Brief is a condensation of his recent in-depth article with reasons for these major production shifts that he labels “The Insourcing Boom.” View the PDF: The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S |
August 2010 article reports on plans for significant production moving back from far-flung locations such as China; 400 jobs in the case of GE, 2000 jobs for components provided by suppliers for Ford. For the complete story and the reasons reported for this “reshoring” movement, View the PDF: USA Today: Manufacturing Heading Back to USA? |
There is a resurgence of manufacturing in the United States as the allure of offshore sourcing begins to fade. Several studies released this year by major consulting firms, and articles in a variety of publications have noted the rise in U. S. production. Examples range from Fortune 500 giant Caterpillar Inc. to toy manufacturer Wham-O Inc., which are either expanding operations here, or bringing back production from offshore suppliers. Die casters are seeing a similar trend, with nearly a quarter of NADCA members reporting they gained new business that had previously been sourced offshore. View the PDF: Rising Wages, Acknowledgment of Hidden Costs Bring Manufacturing Back to U.S. Shores |
A 2-page NADCA report on US jobs and outsourcing. Reviews US job loss and potential return. View the PDF: U.S. Manufacturing… Pain & Promise |
