Application/Tech Briefs

for OEM Product Designers, Engineers & Purchasing Specifiers, and Independent Product Design Consultants

Die Casting Application & Technical Briefs are industry, supplier and CWM white papers published to aid OEMs in optimizing their component designs. They offer greater detail on specific application concerns, and include two design tutorials. These documents, in PDF format, are available from CWM Design Center registered OEMs and OEM Product Design Consultants by immediate download. Adobe Acrobat Reader required for viewing.

USA Today: Special Report on GE, NCR, Cat, Ford—Manufacturing Heading Back to USA?
(No. T39) 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, Download Tech Brief No T39.
Also see book review of "Poorly Made in China," below.

Book Review: "Poorly Made in China;" an American Insider Looks at Current Business Practicies
(No. T38) An American author with a background in Chinese history and years of OEM experience with manuacturers in China updates current practices. Valuable knowledge for any OEM considering offshore sourcing. Download Tech Brief No T38.

The Plastic vs Die Casting Process Decision:
Light Weight, Extra Strength, Shielding & Greener
(No. 37) If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a light weight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands down choice. Download Tech Brief No 37.

Selecting the Best Custom Die Caster for
Your Next Part Production Project
(No. 36) 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. Download Tech Brief No 36.

Functional-Build Approach Offers Lower Production Costs, Higher User Scores
(No. 35) 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. Download Tech Brief No 35.

EPA-Compliant Chromate for Al, Mg & Zn Parts
(No. 34) 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. Download Applic Brief No 34.

Preliminary Guide to Overmolding of Die Cast Parts
(No. 33) Overmolding of a die cast enclosure allows product advantages beyond the soft-touch characteristics of elastomers. Tech Brief outlines design considerations which should be addressed by the design engineer planning a marriage of die casting and elastomer overmolding. Download Applic Brief No 33.

Die Cast Heat Sink Can Be a Cost-Effective OEM Choice
(No. 31) 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. Download Applic Brief No 31.

Die Casting Design Myths That Can Cripple Optimum Production Decisions
(No. 26) 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. Download Tech Brief No 26.

Achieving Superior EMI Shielding with Die Cast Housings
(No. 24) 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. Download Applic Brief No 24.

Magmasoft® Process Simulation Cuts Lead Time, Improves Quality, Lowers Production Costs
(No. 23) 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 construciton. Download Tech Brief No 23.

Tutorial: Design of an Electronic Enclosure for Die Casting Production
(No. T010) 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. Download Applic Brief No T010.

Tutorial: Redesigning a Bracket from a Steel Assembly to Die Casting
(No. T011) 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. Download Applic Brief No T011.

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