CWM News Archive
PRODUCTION DEVELOPMENTS
 CNC Machining Center's Increased to 27
New Mag Option for Chrome-Plated Plastic
EPA-Compliant Chromate for Al, Mg & Zn Parts
Lean Manufacturing Practices to the Next Level
Magmasoft® Assures Critical Cosmetic Success
CWM Marks 70th Year of OEM Services Expansion
New, More Accurate Digital Sensors; Fewer Rejects
China" CDMIA Issues Caution on Die Tooling
SPECIAL DIE CASTING CASE STUDIES
500% Cost Saving: Die Cast vs Machined Brass
IMA Excellence Award for Mg Medical Housing
Ultra-Rugged Specs Met by Hi-Tech Mg Housing
LITERATURE NEWS & RELEASES
NADCA Updates Die Casting Specification Standards
5 Most Popular Die Cast Literature Downloads
Miniature Die Casting Primer Available
NADCA Collaborative Engineering White Paper
ENVIRONMENTAL/SAFETY PERFORMANCE
Outstanding Safety Record Cited Again in '08
CWM Launches New "Green Facilities" Program
As a Green Biz Co. CWM Leads its Industry
INDUSTRY/ASSOCIATION/COMMUNITY ACTIVITY
50th-Yr. Celebration for WT's Industry Career
Eric Treiber Chairs NADCA Govt. Affairs
Chicago Rehab Institute Award to CWM
Walter Treiber Retires IMA Presidential Gavel
CWM CEO Leads IMA to 1st China Conference
NADCA Life Achievement Award to Walter Treiber
PERSONNEL NEWS
Jon Miller Appointed CWM Director of Sales
Engineering Director plus 4 other Appts.
New QA Planning Mgr. Position at CWM
CNC Machining Centers Increased to 27
With the addition of two new Leadwell CNC machining centers to its CNC Machining Division, an MV-40 and MV-50 unit, Chicago White Metal has increased its number of centers to 27, V.P. Brian Andrews announced.
The new Leadwells, in addition to further expanding CWM’s capability for highest RPM spindle speeds and precision, enable still larger parts and more efficient multiple operations to be programmed. A wider range of prototyping, dedicated machining and post-casting machining can be performed in house.
For more on CWM's CNC capabilities, click here.
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500% Cost Saving: Die Cast vs Machined Brass
The low-volume production of a small precision component for a medical device, produced in CNC machined brass, was put through value analysis against possible alternative production efficiencies. Results of the review indicated that a CWM net-shape 4-slide miniature zinc die casting could replace the machined part with no sacrifice in mechanical properties, at a significant cost reduction. The precision component is now being die cast at a 500% unit cost saving.
To download a PDF of the full case study of this part, click here for Miniature Die Casting Case Study No. 39 on the Case Study page in the OEM Die Cast Design Center section.
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NADCA Updates Die Casting Spec Standards
The acknowledged in-depth reference manual on product standards for the specification of custom die castings has been updated and released by the North American Die Casting Assn.
Among comprehensive alloy and related data is new information on RoHS and REACH compliance; a new simplified formula for calculating draft angles; information on tools for improving Product Integrity and First Article Inspection Requirements; and expanded information on avoiding porosity. Updated specification drawings have been added throughout.
The updated 2009 edition of this 220-page $120 "Product Standards" Manual is available to OEM product designers, engineers & purchasers, as well as independent product design consultants registered at CWM's OEM Resource Center, for the special CWM discount price of $75. It is also available from your CWM Regional Sales Representative.
For more details on the NADCA Product Standards Manual and special CWM Discount Order Form, go to: NADCA Standards Manual.
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5 Most Popular Diecast Literature Downloads
Over 7,800 die casting design and production documents have been downloaded in PDF format by OEM visitors to the OEM Die Cast Design Center of Chicago White Metal Casting's website. Here are the five most popular downloads (over 1,040 downloads have been made of CWM's "Design & Specification Guide" alone):
Design & Spec Guide for Custom Parts
16-pages, at the Design Guide Section
12 Ways to Reduce Costs of Die Cast Parts
6-pages, at the Design Guide Section
Quick Guide to Die Cast Surface Finishing
8-pages, at the Design Guide Section
Evaluating Materials & Processes
4-pages, at the Engineering Bulletin Section
Design & Production Preplanning
1-page, at the Engineering Bulletin Section
In addition to the over 70 such custom design guides, bulletins and tech-briefs available-- published by CWM and industry sources-- there is a Frequently Asked Question section on die casting design and production subjects. Plus a Webinar section of 5-min. to 10-min. Online Webinars that can be viewed free, 24/7. After completing a brief registration, OEMs can return to the Design Center at any time using only their email address.
For a Quick Tour of the OEM Die Cast Design Center, Click Here.
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50th-Yr. Celebration for WT's Industry Career
Employee associates, former employees, long-time sales reps, suppliers, industry friends and colleagues, as well as his wife Carolyn and his extended family of four children and many grand-children gathered at CWM in a surprise June celebration of CEO Walter Treiber's career.
The event highlighted the beginning of his 50th year devoted to the industry and the organization he loves.
Heartfelt toasts were made. Milestones in technology advancements, awards and association activities that have helped grow the die casting industry were noted in a moving speech by his son Eric, as CWM president and COO the third Treiber generation to lead the company.
Founded in a Chicago loft above a fish market in 1937 by Walter Treiber, Sr., under his son's leadership CWM
has grown to a state-of-the-art 136,000 sq. ft. plant and office facility serving leading high-technology OEMs worldwide.
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Outstanding Safety Record Cited Again for '08
Chicago White Metal Casting again received an Outstanding Safety Award from the North American Die Casting Association. One of a select group of die casters presented with the 2008 award, CWM repeated its safety peformance which brought it the award in 2007.
The annual NADCA Safety Award recognizes die casting industry companies that have met or exceeded industry criteria for operating a safe working environment for their employees, covering total operations whose reportable injury or illness level was below the national average of 7.0 for all manufacturing companies. Back to Top
New Mag Option for Chrome-Plated Plastic
The superior mechanical qualities of magnesium can now be combined with a premium cosmetic plated finish offering product designers a cost-effective new option. New joint material and process finishing developments have brought quality electroplating to Mg die casting for a wide range of new applications.
The new mag chrome-plated surface finishes for die cast housings and components are comparable to that achievable in high-quality zinc parts and superior to that of molded plastic.
Quality chrome plating for thin-wall, lightweight mag has long been a goal when an alternative to a painted surface was desired. Chicago White Metal Casting can now offer mag’s superior advantages in rigidity, impact strength and dent resistance with a premium-plated finish, at part weights comparable to plastic. Excellent heat dissipation and built-in EMI/RFI shielding are added benefits of Mg. The costly inserts often required for plastic parts can be eliminated.
For more on how this new Mag Alloy and Chrome Electroplating development could benefit your product planning, Email the CWM Sales Dept. or call 630-595-4424.
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Primer on Miniature Die Casting Released
Special CWM Engineering Bulletin No. 76 provides OEMs with a condensed overview on how Miniature Zn & ZA-8 high-speed die casting process is the most cost-effective technology for small, complex structural parts.
This bulletin outlines the essential facts design engineers and purchasers should know about today's specialized machines, the types of component parts that qualify, the part design guidelines the process requires be followed, and cost and lead-time considerations.
To go directly to the OEM Die Cast Design Center's "Engineering Bulletin" section to download this new Bulletin, click here.
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Lean Manufacturing Practices to the Next Level
As part of its program of aggressively pursuing best lean practices, CWM has formalized lean manufacturing in its production procedures, incorporating continuing in-house training. The CWM program is based on in depth reviews of the successful lean programs of its largest customers, with successful backgrounds in the formal application of lean manufacturing principles. CWM team members participated in comprehensive lean training sessions incorporating Kaisan events and Value Stream Mapping.
The lean manufacturing program at CWM has demonstrated its continuing effectiveness in revealing improvement opportunities.
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NADCA Collaborative Engineering White Paper
This in-depth White Paper from the North American Die Casting Assn., offered by CWM, details 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.
For the free PDF download of this NADCA Engineering Bulletin on "Collaborative Engineering," go to the "Engineering Bulletin" section of CWM's Web OEM Dis Cast Design Center (one of 9 resource sections, with over 70 free design guides & aids). To go to the Center's entry page, click here.
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Eric Treiber Chairs NADCA Govt. Affairs
Eric Treiber, CEO and President of CWM, has been named Chairman of the North American Die Casting Association's Government Affairs Committee, it was announced by Dan Twarog, President of NADCA.
Fostering Alliances for the Industry
This Committee, on behalf of the entire die casting industry, is charged with aiding the fostering of strategic alliances with legislators in Washington and increasing the effectiveness of grassroots efforts of industry companies in helping achieve a positive legislative agenda. Its current program is focussed on the importance of retaining a strong, competitive manufacturing base in the U.S.
Eric brings to his chairmanship a background in helping develop industry-wide relationships with the U.S. EPA, which included participation in the agency’s Sustainable Industries Metalcasting Sector Program, plus the SF6 Emission Reduction Partnership for the Magnesium Industry.
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CWM Launches New "Green Facilities" Program
Building on its ISO 14001 environmental certification commitments, CWM is launching an expanded program of “Green Facilities Initiatives” to further reduce its ecological footprint in its offices & production facilities.
Targeting landfill avoidance, waterways improvement and energy conservation, this program will further enhance CWM activities in recycling production scrap, plastic shrink film, pallets, batteries, packaging containers, corrugated material, office paper, and in reducing chemical & process water usage.
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Ultra-Rugged Specs Met by Hi-Tech Mg Housing
The new GR-3 GPS satellite tracking unit from Topcon Positioning Systems is a major breakthrough in technology.
Project managers at Topcon wanted the GR-3 enclosure to be as advanced as the technology inside: ultra rugged and durable but lightweight for portable field use; waterproof; dustproof, with fail-safe EMI shielding. A high-tech CWM hot-chamber magnesium die casting was the clear housing choice-- shock rated to survive 6.5 t. pole drops to concrete.
To examine full design and production details on this outstanding enclosure, click here for more on the PDF (CWM Case Study #38) in the Case Study section of the OEM Die Cast Design Center. Back to Top
As a Green Biz Co. CWM Leads its Industry
Based on its environmental leadership practices and participation in the EPA's National Environmental Performance Track program, Chicago White Metal Casting has been recognized as a GreenBiz Leader company, the first and, we believe, still the only custom die casting facility so named by the U.S. Environmental Protection Agency.
This EPA's programs recognize and encourage top environmental performers— those who go beyond compliance with regulatory requirements to attain levels of environmental performance and management that benefit people, communities, and the environment.
CWM's GreenBiz Leader recognition is the latest in a series of environmental initiatives and achievements leading its industry:
 1st to achieve ISO 14001 Certification
1st participant in EPA's Performance Track Program
Member of EPA's Sustainable Industries Partnership
And, of course, producer of Recyclable Products form Recyclable Alloys.
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Chicago Rehabilitation Institute Award to CWM
By implementing a plan to help an employee transition back into the working world after a stroke, Chicago White Metal has earned the 2007 Corporate Award from the prestigious Rehabilitation Institute of Chicago, which is dedicated to helping people with physical disabilities live a fulfilling life.
"CWM needed to work closely with the employee's rehabilitation case worker to review, organize and monitor his work schedules, workload and overall physical condition," according to Anne Andrews, newly appointed CWM Human Resources Manager. "We did this with the guidance of his direct supervisor and the managers of several CWM departments to determine what the optimum permanent fit would be for him at Chicago White Metal Casting."
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Jon Miller Appointed CWM Director of Sales
President Eric Treiber announced the appointment of Jonathan (Jon) Miller as CWM Director of Sales. He is supervising all sales activities, including managing the CWM force of sales-engineers which serve OEMs from major cities in the U.S., as well as Canada and Mexico.
He joined CWM with 24 years of experience in the die casting industry, including 20 years in sales, marketing and engineering for one of the largest custom magnesium die casters in North America. His earlier Al and Zn die casting industry experience was as a die cast Quality Assurance Manager and as a Quality Engineer and Production Supervisor. He is a past American Society of Quality Control certified quality engineer, and a current member of the North American Die Casting Association and the International Magnesium Association, where he has served as a speaker, program chairman, and committee member.
Jon holds a Bachelor of Science degree in Business Administration and Systems Analysis from Taylor University and a Graduate Certificate in Business Administration from the Keller School of Management.
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New Engineering Director plus 4 other Appts.
Steve Wojtal: Director of Engineering
Formerly Tool & Die Dept. Mgr., Steve has been appointed CWM Director of Engineering, bringing his deep tooling knowledge and years of experience to his new role. Among other duties he will be overseeing the design and construction of all CWM tooling and supervising the work of the project engineering staff. Steve joined CWM in 1979.
Tom Mrock: New Program Introduction Manager
In this newly created NPI position, Tom will be interfacing with customers, CWM personnel and suppliers in the early phases of newly awarded, as well as potential, programs to establish the optimum finishing process. He joined CWM in 1983.
Dave Crevie: Tool & Die Dept. Supervisor
Moving from Tool & Die Dept. Asst. Mgr., Dave will be overseeing all work in the maintenance and repair of production tooling. He is a 22-year CWM veteran.
Dan O’Connor: Director of Purchasing
Dan, who joined CWM in 1984, will be directing personnel engaged in procuring services, components and supplies,
as well as material handling activities in the Traffic Dept.
He was formerly Manager of Traffic & Material Handling.
Francisco Acosta: Traffic Supervisor
Francisco, a former Purchasing Component Expeditor, will be coordinating all materials shipments & receipt of deliveries.
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New QA Planning Mgr. Position at CWM
Sylvia Garcia has been appointed to the new position of CWM's QA Planning Manager, it was announced by Bill Baraglia, VP, Manufacturing. She is responsible for establishing all dimensional appraisal procedures for die castings and related components.
The goal of this new position is to provide more timely feedback to further improve product quality and reliability. Sylvia brings significant experience to the new function, including 14 years in all quality departments of a major auto parts stamping company.
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CWM Marks 70th Year of OEM Services Expansion
Chicago White Metal Casting was founded in 1937 in a loft building in the center of Chicago by Walter G. Treiber, Sr. and Samuel Gullo. As a custom die caster of recyclable alloys, the company operates today under 2nd & 3rd-generation Treiber family management from a modern 136,000 sq. ft. facility in Bensenville, Illinois.
From Zn to Al to Mg and Beyond. An early adopter of thin-wall zinc technology for hot-chamber die casting, CWM promoted Zn for complex, lighter-weight and lower-cost parts. With the addition of cold-chamber aluminum die casting machines, CWM soon integrated successive porosity-reduction techniques into Al part production. Today CWM engineers are leveraging the processing predictability of the Magmasoft® die casting software simulation system to optimize net-shape aluminum die cast components.
A Pioneer in Hot-Chamber Mg Production. CWM became a pioneer in hot-chamber magnesium die casting as the first North American custom die caster to offer this advanced, faster-cycling process. Its Mg experience has set the standard for close-toleranced, thin-wall, net- and near-net shape Mg housings: it operates the largest custom hot-chamber Mg department in North America. And today the cost-efficiency of miniature Zn & ZA-8 die casting is now offered.
High-precision in-house CNC machining, as well as complete contract manufacturing and assembly, became a part of CWM’s broadened services. CWM and its divisions are ISO 9001 registered and its environmental management systems 14001 registered, with best-in-class environmental practices recognized by EPA. For more on CWM capabilities, see the Capabilities Section.
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Lean Manufacturing Practices to the Next Level
As part of its program of aggressively pursuing best lean practices, CWM has formalized lean manufacturing in its production procedures, incorporating continuing in-house training.
The CWM program is based on in-depth reviews of the successful lean programs of its largest customers, with successful backgrounds in the formal application of lean manufacturing principles. CWM team members participated in comprehensive lean training sessions incorporating Kaisan events and Value Stream Mapping.
The lean manufacturing program at CWM is demonstrating its continuing effectiveness in revealing significant improvement opportunities.
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Walter Treiber Retires IMA Presidential Gavel
In recognition of the importance of association activity to growing the world-wide market for magnesium die castings, Chicago White Metal Casting has been a 22-year company member of the International Magnesium Association. And CWM CEO Walter Treiber has made a continuing personal commitment to the work of this association in a variety of capacities.
Walter has served two separate spans as IMA president: the first an unprecedented three consecutive terms from 1990 to 1993 and the last a two-term stint from 2005 to 2007, after which he is retiring his IMA presidential gavel. He continues as a member of the IMA Executive Committee and the Board of Directors.
Special “Mag Promotion Award.” CWM was the only member company to receive a special IMA award for “Promoting Magnesium Die Casting,” and has been the recipient of many “Magnesium Die Casting Design Excellence Awards.” Chicago White Metal and Oskar Frech GmbH & Co. partnered to develop the world’s largest capacity hot-chamber Mg die casting machine, which won the IMA’s “Process Award of Excellence” in 1989. See the Home Page for photos of some of the latest CWM Mg applications.
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EPA-Compliant Chromate for Al, Mg & Zn Parts
Environmentally friendly trivalent chromium is now a proven, economical alternative to hexavalent chromium coatings, offering high corrosion resistance for CWM Al, Mg and Zn die castings in a range of applications.
With a bright, cosmetically pleasing finish, this alternative combined conversion-functional coating meets stricter commercial and U.S. and European Union environmental mandates, avoiding the concerns with prohibited products using toxic hexavalent chromates.
Results of tests to ASTM standards demonstrate salt-spray protection up to 168 hours on Aluminum alloy 380.
(For a printed CWM "Tech Brief" on the latest information regarding Trivalent Chromium coating for die castings, contact your CWM Regional Sales-Engineering Representative or the CWM Sales Dept., or download Tech Brief No. 34 in the Application/Tech Brief section of the OEM Die Cast Design Center)
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Magmasoft® Assures Critical Cosmetic Success
Critical cosmetic plated finish requirements for die cast component surfaces has always been one of the most exacting specifications for the die casting process. A current project for an aluminum die cast dome-shaped design required a gold-plated finish: the combination of this plating specification and the part's shape meant the optimum surface finish challenge.
After inputting the customer's CAD files and developing the optimal tooling design for the project, use of advanced Magmasoft® process simulation software in-house enabled CWM engineers to predict the effects of final metal flow on the part's critical surface. After a series of precise tooling design iterations and repeat simulations, the design was released for die tooling construction. The final result: first-shot success.
Interfacing with extensive databases and its 3D modeler, the new software allows rapid analysis of a product’s design, tooling, and process variables prior to die construction. CWM engineers believe that the Magmasoft system is, today, the best predictor of the performance of a die casting die design. It provides a best estimate of the mechanical properties that can be expected in the final cast part.
The bottom line for OEMs by CWM's use of this advanced system is reduced lead time, improved quality assurance, and lower costs of manufacturing. Arrange a visit to CWM to see CWM’s Magmasoft workstation in action.
(A CWM "Guide to Surface Finishing" for die castings, containing design tips for better finishing results and alternative finishing cost comparisons, can be downloaded from the Design Guide Section in the OEM Die Cast Design Center. For more on Magmasot simulation, see the Applic/Tech Brief Section. To arrange a CWM Plant visit to see Magmasoft metal flow simulation in action, contact your CWM Regional Sales-Engineering Representative or the CWM Sales Dept.)
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CWM CEO Leads IMA to 1st China Conference
In pursuit of the goal of the International Magnesium Assn. to promote wider worldwide use of magnesium, the IMA held its first Annual World Magnesium Conference in Beijing, China, jointly organized by the China Magnesium Assn. Walter Treiber, CWM CEO, led this international industry conclave of lectures and exhibits as the IMA’s president.
Building the Die Cast Mg Market A major feature of the Conference was the presentation of IMA awards for excellence in magnesium die casting and display of past award-winning examples. CWM has won this award, which promotes new die casting applications, many times in the past.
Die Casting Now Leads All Mg Usage Among the magnesium end-use categories, die casting is now estimated to be the single largest usage category in 2005, and appears on track for continued growth in both the automotive and non-automotive markets.
Magnesium die casting is growing at nearly twice the rate of overall Mg consumption, according to data from the IMA.
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China's CDMIA Issues Caution on Die Tooling
In a candid statement from the China Die and Mold Industry Assn. (CDMIA), its director stated that state ownership suffers a deficient system for producing sophisticated die casting dies and plastic molds based on inadequate numbers of qualified professionals.
According to the association's year-end report, quoted in Design News, one of the biggest problems plaguing Chinese mold making is lack of skilled workers. It states China's tooling industry remains substandard and largely incapable of making highly complex tools. Exported tools are termed mostly medium- or low-grade. A clear note of caution to U.S. OEMs.
For more on CWM capabilities, see this website's Capabilities Section, and click on "How CWM makes the highest quality die cast part at the lowest unit cost."
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IMA Excellence Award to CWM Mg Medical Housing The hot-chamber magnesium die cast housing from CWM for a new cart-based modular ultrasound system received the "Design Award of Excellence" from the International Magnesium Assn. Light weight, durability under abuse, and fail-safe shielding against the ultra-high EMI noise levels of hospital environments were important material and process considerations.
In-depth OEM experience with plastics rejected a resin-based design, based plastic's requirement for thicker walls and the difficulties of assured EMI/RFI shielding, plus inherent lower drop strength.
Both mag die casting and thixotropic metal molding were carefully evaluated. While metal molding could meet the shielding advantages and ruggedness of die cast Mg, it could not meet the minimum wall thicknesses required— achievable with advanced die casting.
For more details on this Medical Housing application, see "Case Studies" in the Die Cast Desgn Center Section.
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Mg Plus Overmolding Equals a Superior Housing
Leading OEM engineering publications have featured the breakthrough design marriage of a CWM mag die cast case with an overmolded polyurethane elastomer.
The new housing, for an advanced Tektronix fiber optic cable tester, offers greater strength and performance over plastic, with part consolidations of the hot-chamber Mg and elastomer unit resulting in a 20% saving compared to similar plastic cases, according to Tektronix engineers. This combination of the two processes is believed to be the first such example incorporating a complex, finely featured magnesium die cast housing.
The application was a cover feature in Design News magazine and was featured in a two-page story in Advanced Materials and Processes magazine. The magnesiusm and elastomer application was a three-page feature in Modern Metals, and was also featured in Product Design and Development.
For a detailed discussion of this "Overmolding" application, see see "Case Studies" in the Die Cast Desgn Center Section.
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New, More Accurate Digital Sensors: Fewer Rejects
To produce die cast parts to precise specifications, molten alloys must be metered and forced into a complex die cavity, at pressures up to 20,000 psi, in about a second. During that second, in an environment of vibration, high heat, fine dust and lubrication mist, a machine sensor must relay the exact position and velocity of the machine's plunger at all points, to 0.001 in.
Reliable sensor feedback has been an industry challenge. CWM is now using linear digital position sensors in its aluminum die casting machines based on enhanced magnetostrictive technology. These new-generation transducers, encased in a specially sealed energy-absorbent package, have the ability to accurately adjust to vibration and temperature changes. The result is better parts, fewer rejects, and lower costs. Back to Top
NADCA Life Achievement Award to Walter Treiber
The North American Die Casting Association presented CWM CEO Walter G. Treiber their Distinguished Life Achievement Award at the International Reception and Awards Banquet during the NADCA 22nd International Die Casting Congress and Exposition.
The award is given in recognition of outstanding contribution to the die casting industry and a long record of service to the association and its predecessors. He is a past recipient of NADCA’s Austin T. Lillegren Award, Doehler Award, and Gullo & Treiber Award. Walter has served as a member of the NADCA Board of Directors, co-chairman of its National Affairs Committee, and as a founding member of NADCA’s Die Casting Development Council and co-chairman of its first Finance Committee.
He has also served as president of the International Magnesium Association and currently as a member of the IMA’s Executive Committee, Board of Directors and as First Vice President. His record includes service as a board member of the Institute of Magnesium Technology.
A pioneer in the introduction of the hot-chamber magnesium die casting process in North America, Walter brought the first hot-chamber magnesium machine to Chicago White Metal Casting in 1978.
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