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Your success is our success. We help companies optimize die casting designs and minimize overall costs.  From design pre-planning, to prototypes, to final finishing, we help our clients achieve high performance.  Our case studies tell the story.

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10 "Mini" Case Studies for Mini Zinc Parts
10 "Mini" Case Studies for Mini Zinc Parts

Miniature zinc die casting is a precision die casting process which addresses the need for smaller component manufacturing.  Learn more about how CWM has helped many different industries with die casting projects in this overview of 10 Case Studies.  OEM Tech Brief 47 (April 2015)



OEMTechBrief47-10-Mini-Zinc-Case-Studies.pdf
 
Redesign Delivers 40% Unit Cost Saving, 8% Less Weight, Superior Performance
Redesign Delivers 40% Unit Cost Saving, 8% Less Weight, Superior Performance

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.



MgProjectorCseStdy.pdf
 
1st-ever Triple Winners in NADCA Die Casting Contest
1st-ever Triple Winners in NADCA Die Casting Contest
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)

3AwdCsStdy.PDF
 
Al Archery Bow NADCA Die Casting Award Winner
Al Archery Bow NADCA Die Casting Award Winner
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)

AlArchryBowCS.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
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 light weight.

AlDrtBikeCsStdy.PDF
 
GPS Satellite Tracker Unit in Rugged, Lightweight Mg
GPS Satellite Tracker Unit in Rugged, Lightweight Mg
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.

MgRgdGPSCS.PDF
 
High-Tech Al & Mg for Advanced Video Imaging System
High-Tech Al & Mg for Advanced Video Imaging System
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.

SonyCmraCsStdy.PDF
 
Intricate Al Die Cast Propane Vaporizer-Regulator
Intricate Al Die Cast Propane Vaporizer-Regulator
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.

AlVprzrCsStdy.PDF
 
Key High-Tech Mg Parts for Optical Survey System
Key High-Tech Mg Parts for Optical Survey 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.

MgTrimbleCS.PDF
 
Medical Imager Mg Multi-function Housing Walls
Medical Imager Mg Multi-function Housing Walls
Two Mg 12 x 17 in. precision die cast housing walls for an all-in-one multi-media desktop medical imager provide light weight, multiple functions and reduced part counts. Each high-tech hot-chamber mag die casting delivers 25 tight-toleranced features as-cast.

MgImagerCS.pdf
 
Mg Die Cast Professional Digital Camera Case
Mg Die Cast Professional Digital Camera Case
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, light weight and the quality feel of metal.

MgKdkCmraCS.pdf
 
Mg Die Cast Ultrasound Portable Workstation Housing
Mg Die Cast Ultrasound Portable Workstation Housing
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.

LghtrPlstcEMIShldCS.pdf
 
Mg IMA Process Technology Award for Auto Mirror
Mg IMA Process Technology Award for Auto Mirror
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)

MgInDegateGtxAwdCS.PDF
 
Only Mg Met Strength-Weight Specs for Voice/Data Unit
Only Mg Met Strength-Weight Specs for Voice/Data Unit
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.

MgT-BerdCS.PDF
 
Portable Die Cast Mg Case with Elastomer Overmolding
Portable Die Cast Mg Case with Elastomer Overmolding
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.

MgHsgOvrmldBrkThrghCS.PDF
 
Replacement for Machined Brass at a 500% Savings
Replacement for Machined Brass at a 500% Savings
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.

Brss2Zn_CstSvgs.PDF
 
Rugged Al Die Cast Laser Housing Outperforms Plastic
Rugged Al Die Cast Laser Housing Outperforms Plastic
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. New model offers an Al die cast metal housing to meet extreme, rugged field conditions, difficult for plastic housings to survive.

AlPipeLsrCsStdy.PDF
 
Rugged Mg Spotting Scope Die Casting Award
Rugged Mg Spotting Scope Die Casting Award
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).

MgSpotScpCS.PDF
 
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