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With 75 years of knowledge and experience, we’ve become the A-Z die casting authority
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CWM’s Design Center is a valuable free resource tool to aid you when designing for die cast products. You’ll get access to an educational hub—the largest collection of technical die casting content in the industry—geared to assist OEM design engineers, purchasing specifiers, and OEM design consultants through the die casting process. Choose from over 75 technical die casting documents, webinars, and movies to view online or download. Purchase NADCA standards at a discounted price, all with a free subscription. Tour the library: Browse the library of die casting content available by clicking on any topic below or use our search feature. Click + to view / hide answers |
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Inside CWM Newsletter
| Inside CWM Newsletter - 2017 Winter | |
| In this issue you will find the following stories: New Employees, Retirements, Condolences, NEW CWM Guides, Design Awards, Perpsectives, CWM Investments, Health Fair 2017, Charitable Efforts, CWM and the Morton Arboretum, and more! InsideCWMWinter2017.pdf |  |
| Inside CWM Newsletter - 2017 Summer | |
| 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! InsideCWMSummer2017.pdf |  |
| Inside CWM Newsletter - 2017 Spring | |
| 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! InsideCWMSpring.2017.pdf |  |
| Inside CWM Newsletter - 2016 Fall | |
| 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! Inside CWMFall.2016.digital.pdf |  |
| Inside CWM Newsletter - 2016 Spring | |
| 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! InsideCWMv121.pdf |  |
| Inside CWM Newsletter - 2015 Fall | |
| 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! InsideCWv112.pdf |  |
| Inside CWM Newsletter - 2015 Spring | |
| 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! InsideCWv111.pdf | |
| Inside CWM Newsletter - 2014 Fall | |
| 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! InsdeCWv102.pdf | |
| 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! InsideCWv101.pdf | |
| Inside CWM Newsletter - 2013 Spring | |
| In this issue you will find the following stories: CWM Partners with Harper Manufacturing Program, CWM's New Brother, Zoo at CWM, Honorary Tribute, Bragging Rights, and more! InsdeCWv91.pdf | |
| Inside CWM Newsletter - 2012 Winter | |
| 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! InsdeCWv81.pdf | |
| Inside CWM Newsletter - 2012 Summer | |
| 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! InsdeCWv82.pdf | |
| Inside CWM Newsletter - 2011 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! InsdeCWv72.pdf | |
| Inside CWM Newsletter - 2011 Spring | |
| 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! InsdeCWv71.pdf | |
| Inside CWM Newsletter - 2010 Fall | |
| In this issue you will find the following stories: 30th Annual golf Outing, Summer Picnic, Employees of the Month, New Employees, Sales Meeting. InsdeCWv62.pdf | |
| Inside CWM Newsletter - 2010 Winter | |
| 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! InsdeCWv61.pdf | |
| Inside CWM Newsletter - 2009 Fall | |
| 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! InsdeCWv52.pdf | |
| Inside CWM Newsletter - 2009 Spring | |
| 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! InsdeCWv51.pdf | |
| Inside CWM Newsletter - 2008 Fall | |
| 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! InsdeCWv42.pdf | |
| Inside CWM Newsletter - 2008 Spring | |
| 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! InsdeCWv41.pdf |  |
| Inside CWM Newsletter - 2007 Fall | |
| 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! InsdeCWv32.pdf | |
| Inside CWM Newsletter - 2007 Spring | |
| 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! InsdeCWv31.pdf | |
| Inside CWM Newsletter - 2006 Fall | |
| 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! InsdeCWv22.pdf | |
| Inside CWM Newsletter - 2006 Spring | |
| 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! InsdeCWv21.pdf | |
| Inside CWM Newsletter - 2005 Fall | |
| 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! InsdeCWv12.pdf | |
| Inside CWM Newsletter - 2005 | |
| 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! InsdeCWv11.pdf | |
OEM Solutions / Tech Brief
| The Market for Aluminum Alloys in North America: Trends and Challenges | |
| 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. OEMTechBrief50-The-Market-for-Aluminum-Alloys-in-North-America-Trends-Challenges.pdf |  |
| Book Review: "Poorly Made in China" | |
| 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.
PrlyMdChnaTB.pdf |  |
| Converting Machined Parts to Die Casting | |
| 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. ConvMchtoDCtb.PDF |  |
| Design News Engrg Survey & Key DC2 OEM Resources | |
| 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. SlryGains-DCKnowlTB.PDF |  |
| Developing an Optimum Product Design | |
| 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. Dev.Optimum.Prod.Design.pdf |  |
| EPA-Compliant Chromate for Al, Mg & Zn Parts | |
| 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. TriChrmTB.pdf |  |
| Getting on Course After Onshoring | |
| 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. OEMTechBrief48_Getting_On_Course_After_Onshoring.pdf |  |
| How to Select the Best Custom Die Caster | |
| 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. SelBstDCtb.pdf |  |
| Special Industrial Robotics Issue | |
| 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. OEMTechBrief49_Special-Die-Casting-Robotics-Issue.pdf |  |
| Still Believe These Five Magnesium Myths? | |
| A 2-page technical paper. 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. MgMyths.pdf |  |
| The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S | |
| 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.” InsrcBoomTB.PDF |  |
| The U.S. Aluminum Casting Industry | |
| 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) OEMTechBrief45-Aluminum-Die-Casting-Industry.pdf |  |
| USA Today: Manufacturing Heading Back to USA? | |
| 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, MfgBck2USTB.PDF |  |
| The Plastic vs Die Casting Process Decision | |
| 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 MgBenefitsTB.pdf |  |
| Functional-Build Approach to Lower Production Costs | |
| 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. FunctionalBldTB.pdf |  |
| How Magmasoft Process Simulation Lowers Costs | |
| 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. MgmaSftTB.PDF |  |
Apps
Design Pre-Planning
| Developing an Optimum Product Design | |
| 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. Dev.Optimum.Prod.Design.pdf | |
| Superior EMI Shielding with Die Cast Housings | |
| 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. EMIShld4Hsgs.PDF |  |
| Tutorial: Electronic Enclosure Design for Die Casting | |
| 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. NADCA.EnclDsn.pdf |  |
| Tutorial: Redesigning a Steel Bracket 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. NADCABrktDesign.PDF |  |
| Surface Finishes 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. SurfaceFinishesForDieCasting2015.mp4 |  |
| The Die Casting Process: An OEM Designer's Overview | |
| 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. 3CWM_Webinars/CWM_Webinar1/player.php |  |
| The Miniature Zinc Die Casting Advantage | |
| 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. MDCAdvantage.mp4 |  |
| 10 Ways to Reduce the Costs of Die Cast 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. 10Ways.PDF |  |
| 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 |  |
| CWM Al, Mg & Zn Die Cast Production Specs | |
| 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. AlloySpecGd.pdf |  |
| CWM Comprehensive Die Casting Capabilities Brochure | |
| 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. CWM General Brochure.pdf |  |
| Design & Specification Guide for Custom Die Castings | |
| 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. Die-Casting-Design-Specification-Guide-2017.pdf |  |
| Design of a Bracket for Die Casting Production | |
| 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. NADCABrktDesign.PDF |  |
| Designing for Servicing & Recyclability | |
| 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. NADCAProdRcycl.PDF |  |
| Designing Optimum Part Shapes | |
| Introductory guide to developing the optimum component configuration for cost-effective die cast processing. Provides overview of design features which enable the designer to capitalize on the inherent advantages of net-shape die cast production. DesignOptShapes.PDF |  |
| Die Cast Design Myths Can Cripple Optimum Decisions | |
| 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. Dsn_Prod_Myths.pdf |  |
| Die Cast Heat Sink Can Be a Cost-Effective OEM Choice | |
| 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 HeatSnkDsn_Prod.PDF |  |
| Die Cast Zn for Key Computer Structural Component | |
| 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. ZnKeyStructure.PDF |  |
| Die Casting Design & Production Preplanning Guide | |
| 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. Dsn_ProdPreplnGd.pdf |  |
| 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 | |
| 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 | |
| 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 | |
| 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 | |
| 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 |  |
| Leveraging DFM Prior to Design Commitment | |
| 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. 3CWM_Webinars/CWM_Webinar3/player.php |  |
| Machining to Die Casting: A Guide to Conversion | |
| 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. MCDCWebinar5.mp4 |  |
| Magnesium EMI Shielding Characteristics | |
| 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. MG_EMI_Shield.PDF |  |
| 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 | |
| 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 | |
| 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 | |
| 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 |  |
| NADCA Collaborative Engineering White Paper | |
| This in-depth White Paper from the North American Die Casting Assn. 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. NADCA.Coll.Engr.pdf |  |
| NADCA Collaborative Engineering White Paper | |
| In-depth White Paper from the North American Die Casting Assn. details 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. NADCA.Coll.Engr.pdf |  |
| NADCA Design Manual: Intro & Content | |
| Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. NADCA.Prod.Design.DC.PDF |  |
| NADCA-ADCI Standards Cross-Reference Chart | |
| 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) NADCA_StdXref.pdf |  |
| NADCA: Comparison of Mag Die Casting & Plastic Parts | |
| 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. NADCAMg2Plstc.pdf |  |
| NADCA: Coordinate vs Geometric Dimensioning Intro | |
| 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. NADCA_Geo.Dim.pdf |  |
| NADCA: Die Cast Production & Finishing Checklists | |
| 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) NADCAFshngChklst.PDF |  |
| NADCA: For Efficient Manufacturing, Look to Die Casting | |
| 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. NADCAEffctMfg-DC.PDF |  |
| NADCA: Pointers for Designing Die Castings | |
| 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. DsnEngr-DsnPointrs.pdf |  |
| NADCA: Product Standards Manual Overview | |
| 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. NADCA.Prod.Stds.Ovrvw.pdf |  |
| NADCA: Tooling Checklists for Die Casting Dies | |
| 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. NADCAToolChklst.pdf |  |
| 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 |  |
| Overview of CWM Die Casting & Production Capabilities | |
| 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. CWMCapOvrvw.PDF |  |
| 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 |  |
| Preliminary Guide to Overmolding of Die Cast Parts | |
| 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. OvrmldDS.PDF |  |
| Primer on Miniature Zinc & ZA-8 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. MDCPrimer.pdf |  |
| Product Solutions Through 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. DieCastingProdSols.mp4 |  |
| 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 | |
| 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 | |
| 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 |  |
Material Evaluation
| Superior EMI Shielding with Die Cast Housings | |
| 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. EMIShld4Hsgs.PDF | |
| 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 |  |
| 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 | |
| Surface Finishing for Die Casting Bulletin | |
| Brief overview to surface treatment systems for die cast part protection, decoration and improving component performance, for all alloys: Al, Mg, Zn and ZA. NADCASurFin4DC.PDF |  |
| 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 | |
| Magnesium Die Casting: Solutions for Today's Markets | |
| 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. MgSolWbnr.mp4 |  |
| Die Cast Design Myths Can Cripple Optimum Decisions | |
| 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. Dsn_Prod_Myths.pdf | |
| The Plastic vs Die Casting Process Decision | |
| 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 MgBenefitsTB.pdf | |
| Die Cast Zn for Key Computer Structural Component | |
| 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. ZnKeyStructure.PDF | |
| Still Believe These Five Magnesium Myths? | |
| A 2-page technical paper. 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. MgMyths.pdf | |
| Evaluating Materials & Processes | |
| Introductory overview and guide to optimum materials and alternate process selection. Contains a physical and mechanical materials properties comparison chart for the most widely used Al, Mg & Zn die casting alloys. NADCA_Eval_Matl_Processes.pdf |  |
| Tutorial: Redesigning a Steel Bracket 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. NADCABrktDesign.PDF | |
| 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 | |
| Material / Physical Properties Comparison | |
| 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. Material.PropertiesNADCA.12.pdf |  |
| Magnesium EMI Shielding Characteristics | |
| 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. MG_EMI_Shield.PDF | |
| Leveraging DFM Prior to Design Commitment | |
| 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. 3CWM_Webinars/CWM_Webinar3/player.php | |
| 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 | |
| Developing an Optimum Product Design | |
| 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. Dev.Optimum.Prod.Design.pdf | |
| NADCA Design Manual: Intro & Content | |
| Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. NADCA.Prod.Design.DC.PDF | |
| Product Solutions Through 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. DieCastingProdSols.mp4 | |
| 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 | |
| NADCA Standards: Aluminum Alloy Data | |
| Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCA_Al_Alloy.pdf |  |
| Surface Finishes 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. SurfaceFinishesForDieCasting2015.mp4 | |
| 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 | |
| NADCA Standards: Magnesium Alloy Data | |
| Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCA_Mg_Alloy.pdf |  |
| The Die Casting Process: An OEM Designer's Overview | |
| 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. 3CWM_Webinars/CWM_Webinar1/player.php | |
| 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 | |
| NADCA Standards: Zinc & ZA Alloy Data | |
| Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCAZnAllyData.pdf |  |
| The Miniature Zinc Die Casting Advantage | |
| 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. MDCAdvantage.mp4 | |
| 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 | |
| NADCA: Comparison of Mag Die Casting & Plastic Parts | |
| 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. NADCAMg2Plstc.pdf | |
| 10 Ways to Reduce the Costs of Die Cast 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. 10Ways.PDF | |
| 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 | |
| NADCA: For Efficient Manufacturing, Look to Die Casting | |
| 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. NADCAEffctMfg-DC.PDF | |
| Die Cast Heat Sink Can Be a Cost-Effective OEM Choice | |
| 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 HeatSnkDsn_Prod.PDF | |
| 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 | |
| NADCA: Product Standards Manual Overview | |
| 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. NADCA.Prod.Stds.Ovrvw.pdf | |
| Designing for Servicing & Recyclability | |
| 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. NADCAProdRcycl.PDF | |
| 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 | |
| NADCA-ADCI Standards Cross-Reference Chart | |
| 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) NADCA_StdXref.pdf | |
| Die Casting Design & Production Preplanning Guide | |
| 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. Dsn_ProdPreplnGd.pdf | |
| 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 | |
| Primer on Miniature Zinc & ZA-8 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. MDCPrimer.pdf | |
| CWM Comprehensive Die Casting Capabilities Brochure | |
| 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. CWM General Brochure.pdf | |
| 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 | |
| Prototyping for Die Casting in All Alloys | |
| 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. NADCAPrototype.pdf |  |
| CWM Al, Mg & Zn Die Cast Production Specs | |
| 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. AlloySpecGd.pdf | |
| 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 | |
| Quick Guide to Surface Finishing for Al, Mg & Zn 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. SurFinQckGd.pdf |  |
| Design & Specification Guide for Custom Die Castings | |
| 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. Die-Casting-Design-Specification-Guide-2017.pdf | |
| 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 | |
| Converting Machined Parts to Die Casting | |
| 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. ConvMchtoDCtb.PDF | |
| Design News Engrg Survey & Key DC2 OEM Resources | |
| 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. SlryGains-DCKnowlTB.PDF | |
Aluminum
| The Market for Aluminum Alloys in North America: Trends and Challenges | |
| 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) OEMTechBrief50-The-Market-for-Aluminum-Alloys-in-North-America-Trends-Challenges.pdf | |
| 10 Ways to Reduce the Costs of Die Cast 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. 10Ways.PDF | |
| 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 | |
| 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 | |
| CWM Al, Mg & Zn Die Cast Production Specs | |
| 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. AlloySpecGd.pdf | |
| CWM Comprehensive Die Casting Capabilities Brochure | |
| 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. CWM General Brochure.pdf | |
| Design & Specification Guide for Custom Die Castings | |
| 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. Die-Casting-Design-Specification-Guide-2017.pdf | |
| Die Casting Design & Production Preplanning Guide | |
| 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. Dsn_ProdPreplnGd.pdf | |
| 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 | |
| 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 | |
| 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 | |
| Material / Physical Properties Comparison | |
| 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. Material.PropertiesNADCA.12.pdf | |
| NADCA Standards: Aluminum Alloy Data | |
| Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCA_Al_Alloy.pdf | |
| Product Solutions Through 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. DieCastingProdSols.mp4 | |
| Prototyping for Die Casting in All Alloys | |
| 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. NADCAPrototype.pdf | |
| Quick Guide to Surface Finishing for Al, Mg & Zn 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. SurFinQckGd.pdf | |
| 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 | |
| Surface Finishes 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. SurfaceFinishesForDieCasting2015.mp4 | |
| Surface Finishing for Die Casting Bulletin | |
| Brief overview to surface treatment systems for die cast part protection, decoration and improving component performance, for all alloys: Al, Mg, Zn and ZA. NADCASurFin4DC.PDF | |
| The Die Casting Process: An OEM Designer's Overview | |
| 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. 3CWM_Webinars/CWM_Webinar1/player.php | |
| The U.S. Aluminum Casting Industry | |
| 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) OEMTechBrief45-Aluminum-Die-Casting-Industry.pdf | |
Magnesium
| 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 |  |
| Die Casting's Answer to Plastic: Magnesium | |
| 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. DieCastingAnswrToPlasticMagnesium.pdf |  |
| Magnesium Die Casting: Solutions for Today's Markets | |
| 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. MgSolWbnr.mp4 | |
| 10 Ways to Reduce the Costs of Die Cast 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. 10Ways.PDF | |
| 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 | |
| CWM Al, Mg & Zn Die Cast Production Specs | |
| 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. AlloySpecGd.pdf | |
| CWM Comprehensive Die Casting Capabilities Brochure | |
| 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. CWM General Brochure.pdf | |
| Design & Specification Guide for Custom Die Castings | |
| 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. Die-Casting-Design-Specification-Guide-2017.pdf | |
| Die Casting Design & Production Preplanning Guide | |
| 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. Dsn_ProdPreplnGd.pdf | |
| 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 | |
| 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 | |
| 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 | |
| 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 | |
| Magnesium EMI Shielding Characteristics | |
| 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. MG_EMI_Shield.PDF | |
| Material / Physical Properties Comparison | |
| 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. Material.PropertiesNADCA.12.pdf | |
| 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 | |
| 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 | |
| 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 | |
| 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 | |
| NADCA Standards: Magnesium Alloy Data | |
| Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCA_Mg_Alloy.pdf | |
| NADCA: Comparison of Mag Die Casting & Plastic Parts | |
| 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. NADCAMg2Plstc.pdf | |
| 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 | |
| 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 | |
| Product Solutions Through 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. DieCastingProdSols.mp4 | |
| Prototyping for Die Casting in All Alloys | |
| 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. NADCAPrototype.pdf | |
| Quick Guide to Surface Finishing for Al, Mg & Zn 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. SurFinQckGd.pdf | |
| 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 | |
| Still Believe These Five Magnesium Myths? | |
| A 2-page technical paper. 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. MgMyths.pdf | |
| Surface Finishes 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. SurfaceFinishesForDieCasting2015.mp4 | |
| Surface Finishing for Die Casting Bulletin | |
| Brief overview to surface treatment systems for die cast part protection, decoration and improving component performance, for all alloys: Al, Mg, Zn and ZA. NADCASurFin4DC.PDF | |
| The Die Casting Process: An OEM Designer's Overview | |
| 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. 3CWM_Webinars/CWM_Webinar1/player.php | |
| The Plastic vs Die Casting Process Decision | |
| 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 MgBenefitsTB.pdf | |
Zinc
| NADCA Design Manual: Intro & Content | |
| Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. NADCA.Prod.Design.DC.PDF | |
| Material / Physical Properties Comparison | |
| 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. Material.PropertiesNADCA.12.pdf | |
| NADCA Standards: Zinc & ZA Alloy Data | |
| Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCAZnAllyData.pdf | |
| Primer on Miniature Zinc & ZA-8 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. MDCPrimer.pdf | |
| Prototyping for Die Casting in All Alloys | |
| 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. NADCAPrototype.pdf | |
| Quick Guide to Surface Finishing for Al, Mg & Zn 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. SurFinQckGd.pdf | |
| Surface Finishing for Die Casting Bulletin | |
| Brief overview to surface treatment systems for die cast part protection, decoration and improving component performance, for all alloys: Al, Mg, Zn and ZA. NADCASurFin4DC.PDF | |
| Product Solutions Through 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. DieCastingProdSols.mp4 | |
| Surface Finishes 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. SurfaceFinishesForDieCasting2015.mp4 | |
| The Die Casting Process: An OEM Designer's Overview | |
| 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. 3CWM_Webinars/CWM_Webinar1/player.php | |
| The Miniature Zinc Die Casting Advantage | |
| 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. MDCAdvantage.mp4 | |
| 10 Ways to Reduce the Costs of Die Cast 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. 10Ways.PDF | |
| CWM Al, Mg & Zn Die Cast Production Specs | |
| 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. AlloySpecGd.pdf | |
| CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data | |
| 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. CWM.MDC.CapGd.pdf |  |
| Design & Specification Guide for Custom Die Castings | |
| 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. Die-Casting-Design-Specification-Guide-2017.pdf | |
| Die Cast Zn for Key Computer Structural Component | |
| 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. ZnKeyStructure.PDF | |
| 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 | |
Miniature Zinc
| Converting Machined Parts to Die Casting | |
| 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. ConvMchtoDCtb.PDF | |
| Primer on Miniature Zinc & ZA-8 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. MDCPrimer.pdf | |
| The Miniature Zinc Die Casting Advantage | |
| 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. MDCAdvantage.mp4 | |
| CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data | |
| 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. CWM.MDC.CapGd.pdf | |
| 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 | |
Standards / Specifications
| CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data | |
| 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. CWM.MDC.CapGd.pdf | |
| Design of a Bracket for Die Casting Production | |
| 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. NADCABrktDesign.PDF | |
| Material / Physical Properties Comparison | |
| 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. Material.PropertiesNADCA.12.pdf | |
| NADCA Commercial Practices for Die Casting Buyers | |
| 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. 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. NADCACommlBuyPract.pdf |  |
| NADCA Standards: Aluminum Alloy Data | |
| Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCA_Al_Alloy.pdf | |
| NADCA Standards: Magnesium Alloy Data | |
| Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCA_Mg_Alloy.pdf | |
| NADCA Standards: Zinc & ZA Alloy Data | |
| Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCAZnAllyData.pdf | |
| NADCA: Coordinate vs Geometric Dimensioning Intro | |
| 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. NADCA_Geo.Dim.pdf | |
| NADCA: Die Cast Production & Finishing Checklists | |
| 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) NADCAFshngChklst.PDF | |
| NADCA: Product Standards Manual Overview | |
| 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. NADCA.Prod.Stds.Ovrvw.pdf | |
| NADCA: Tooling Checklists for Die Casting Dies | |
| 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. NADCAToolChklst.pdf | |
| NADCA-ADCI Standards Cross-Reference Chart | |
| 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) NADCA_StdXref.pdf | |
| Die Casting Design & Production Preplanning Guide | |
| 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. Dsn_ProdPreplnGd.pdf | |
| CWM Comprehensive Die Casting Capabilities Brochure | |
| 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. CWM General Brochure.pdf | |
| CWM Al, Mg & Zn Die Cast Production Specs | |
| 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. AlloySpecGd.pdf | |
Tooling
| NADCA: Tooling for Die Casting | |
| Learn more about the Die Cast Die with this document, taken from the NADCA Standards Book (2015). NADCA2015DieCastTooling.pdf |  |
| How Magmasoft Process Simulation Lowers Costs | |
| 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. MgmaSftTB.PDF | |
| NADCA Collaborative Engineering White Paper | |
| In-depth White Paper from the North American Die Casting Assn. details 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. NADCA.Coll.Engr.pdf | |
| NADCA Commercial Practices for Die Casting Buyers | |
| 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. 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. NADCACommlBuyPract.pdf | |
| NADCA: Tooling Checklists for Die Casting Dies | |
| 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. NADCAToolChklst.pdf | |
| Machining to Die Casting: A Guide to Conversion | |
| 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. MCDCWebinar5.mp4 | |
| Product Solutions Through 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. DieCastingProdSols.mp4 | |
| The Die Casting Process: An OEM Designer's Overview | |
| 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. 3CWM_Webinars/CWM_Webinar1/player.php | |
| The Miniature Zinc Die Casting Advantage | |
| 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. MDCAdvantage.mp4 | |
| 10 Ways to Reduce the Costs of Die Cast 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. 10Ways.PDF | |
| Die Cast Heat Sink Can Be a Cost-Effective OEM Choice | |
| 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 HeatSnkDsn_Prod.PDF | |
| NADCA Collaborative Engineering White Paper | |
| This in-depth White Paper from the North American Die Casting Assn. 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. NADCA.Coll.Engr.pdf | |
| Design & Specification Guide for Custom Die Castings | |
| 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. Die-Casting-Design-Specification-Guide-2017.pdf | |
Machining
| NADCA Standards: Aluminum Alloy Data | |
| Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCA_Al_Alloy.pdf | |
| NADCA Standards: Magnesium Alloy Data | |
| Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCA_Mg_Alloy.pdf | |
| NADCA Standards: Zinc & ZA Alloy Data | |
| Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCAZnAllyData.pdf | |
| Leveraging DFM Prior to Design Commitment | |
| 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. 3CWM_Webinars/CWM_Webinar3/player.php | |
| Machining to Die Casting: A Guide to Conversion | |
| 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. MCDCWebinar5.mp4 | |
| The Die Casting Process: An OEM Designer's Overview | |
| 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. 3CWM_Webinars/CWM_Webinar1/player.php | |
| 10 Ways to Reduce the Costs of Die Cast 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. 10Ways.PDF | |
| Overview of CWM Die Casting & Production Capabilities | |
| 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. CWMCapOvrvw.PDF | |
| CWM Comprehensive Die Casting Capabilities Brochure | |
| 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. CWM General Brochure.pdf | |
| CWM Al, Mg & Zn Die Cast Production Specs | |
| 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. AlloySpecGd.pdf | |
| CWM CNC Machining Capabilities Brochure | |
| 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. CWM.CNC.Broch.pdf |  |
| NADCA Collaborative Engineering White Paper | |
| This in-depth White Paper from the North American Die Casting Assn. 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. NADCA.Coll.Engr.pdf | |
| Design & Specification Guide for Custom Die Castings | |
| 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. Die-Casting-Design-Specification-Guide-2017.pdf | |
| 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 | |
| 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 | |
Finishing
| NADCA Standards: Zinc & ZA Alloy Data | |
| Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCAZnAllyData.pdf | |
| NADCA: Die Cast Production & Finishing Checklists | |
| 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) NADCAFshngChklst.PDF | |
| Preliminary Guide to Overmolding of Die Cast Parts | |
| 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. OvrmldDS.PDF | |
| Quick Guide to Surface Finishing for Al, Mg & Zn 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. SurFinQckGd.pdf | |
| Surface Finishing for Die Casting Bulletin | |
| Brief overview to surface treatment systems for die cast part protection, decoration and improving component performance, for all alloys: Al, Mg, Zn and ZA. NADCASurFin4DC.PDF | |
| Tutorial: Electronic Enclosure Design for Die Casting | |
| 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. NADCA.EnclDsn.pdf | |
| Leveraging DFM Prior to Design Commitment | |
| 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. 3CWM_Webinars/CWM_Webinar3/player.php | |
| Surface Finishes 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. SurfaceFinishesForDieCasting2015.mp4 | |
| The Die Casting Process: An OEM Designer's Overview | |
| 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. 3CWM_Webinars/CWM_Webinar1/player.php | |
| The Miniature Zinc Die Casting Advantage | |
| 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. MDCAdvantage.mp4 | |
| 10 Ways to Reduce the Costs of Die Cast 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. 10Ways.PDF | |
| Overview of CWM Die Casting & Production Capabilities | |
| 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. CWMCapOvrvw.PDF | |
| EPA-Compliant Chromate for Al, Mg & Zn Parts | |
| 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. TriChrmTB.pdf | |
| CWM Al, Mg & Zn Die Cast Production Specs | |
| 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. AlloySpecGd.pdf | |
| NADCA Commercial Practices for Die Casting Buyers | |
| 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. 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. NADCACommlBuyPract.pdf | |
| Design & Specification Guide for Custom Die Castings | |
| 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. Die-Casting-Design-Specification-Guide-2017.pdf | |
| NADCA Standards: Aluminum Alloy Data | |
| Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCA_Al_Alloy.pdf | |
| 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 | |
| NADCA Standards: Magnesium Alloy Data | |
| Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCA_Mg_Alloy.pdf | |
| Die Cast Zn for Key Computer Structural Component | |
| 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. ZnKeyStructure.PDF | |
Cost of Die Casting
| Machining to Die Casting: A Guide to Conversion | |
| 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. MCDCWebinar5.mp4 | |
| 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 | |
| Product Solutions Through 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. DieCastingProdSols.mp4 | |
| 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 | |
| Surface Finishes 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. SurfaceFinishesForDieCasting2015.mp4 | |
| 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 | |
| The Miniature Zinc Die Casting Advantage | |
| 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. MDCAdvantage.mp4 | |
| 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 | |
| 10 Ways to Reduce the Costs of Die Cast 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. 10Ways.PDF | |
| 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 | |
| Die Cast Heat Sink Can Be a Cost-Effective OEM Choice | |
| 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 HeatSnkDsn_Prod.PDF | |
| 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 | |
| CWM Al, Mg & Zn Die Cast Production Specs | |
| 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. AlloySpecGd.pdf | |
| 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 | |
| CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data | |
| 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. CWM.MDC.CapGd.pdf | |
| 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 | |
| Converting Machined Parts to Die Casting | |
| 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. ConvMchtoDCtb.PDF | |
| NADCA Collaborative Engineering White Paper | |
| This in-depth White Paper from the North American Die Casting Assn. 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. NADCA.Coll.Engr.pdf | |
| Magnesium Die Casting: Solutions for Today's Markets | |
| 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. MgSolWbnr.mp4 | |
| Functional-Build Approach to Lower Production Costs | |
| 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. FunctionalBldTB.pdf | |
| Design & Specification Guide for Custom Die Castings | |
| 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. Die-Casting-Design-Specification-Guide-2017.pdf | |
| Hidden Costs of Sourcing Die Castings Offshore | |
| 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. HiddenCstsOffshr-Byr.PDF |  |
| 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 | |
| How Magmasoft Process Simulation Lowers Costs | |
| 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. MgmaSftTB.PDF | |
| Die Cast Zn for Key Computer Structural Component | |
| 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. ZnKeyStructure.PDF | |
| NADCA Collaborative Engineering White Paper | |
| In-depth White Paper from the North American Die Casting Assn. details 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. NADCA.Coll.Engr.pdf | |
| 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 | |
| NADCA: Pointers for Designing Die Castings | |
| 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. DsnEngr-DsnPointrs.pdf | |
| 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 | |
| The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S | |
| 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.” InsrcBoomTB.PDF | |
| 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 | |
| USA Today: Manufacturing Heading Back to USA? | |
| 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, MfgBck2USTB.PDF | |
| 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 | |
Conversion
| 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 | |
| 10 Ways to Reduce the Costs of Die Cast 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. 10Ways.PDF | |
| Converting Machined Parts to Die Casting | |
| 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. ConvMchtoDCtb.PDF | |
| Design of a Bracket for Die Casting Production | |
| 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. NADCABrktDesign.PDF | |
| Die Cast Heat Sink Can Be a Cost-Effective OEM Choice | |
| 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 HeatSnkDsn_Prod.PDF | |
| Evaluating Materials & Processes | |
| Introductory overview and guide to optimum materials and alternate process selection. Contains a physical and mechanical materials properties comparison chart for the most widely used Al, Mg & Zn die casting alloys. NADCA_Eval_Matl_Processes.pdf | |
| Leveraging DFM Prior to Design Commitment | |
| 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. 3CWM_Webinars/CWM_Webinar3/player.php | |
| Machining to Die Casting: A Guide to Conversion | |
| 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. MCDCWebinar5.mp4 | |
| Magnesium Die Casting: Solutions for Today's Markets | |
| 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. MgSolWbnr.mp4 | |
| NADCA Design Manual: Intro & Content | |
| Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. NADCA.Prod.Design.DC.PDF | |
| NADCA: Comparison of Mag Die Casting & Plastic Parts | |
| 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. NADCAMg2Plstc.pdf | |
| 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 | |
| Primer on Miniature Zinc & ZA-8 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. MDCPrimer.pdf | |
| Product Solutions Through 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. DieCastingProdSols.mp4 | |
| 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 | |
| The Miniature Zinc Die Casting Advantage | |
| 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. MDCAdvantage.mp4 | |
| The Plastic vs Die Casting Process Decision | |
| 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 MgBenefitsTB.pdf | |
| Tutorial: Electronic Enclosure Design for Die Casting | |
| 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. NADCA.EnclDsn.pdf | |
| Tutorial: Redesigning a Steel Bracket 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. NADCABrktDesign.PDF | |
Prototypes
| Prototyping for Die Casting in All Alloys | |
| 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. NADCAPrototype.pdf | |
| Leveraging DFM Prior to Design Commitment | |
| 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. 3CWM_Webinars/CWM_Webinar3/player.php | |
| Machining to Die Casting: A Guide to Conversion | |
| 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. MCDCWebinar5.mp4 | |
| Overview of CWM Die Casting & Production Capabilities | |
| 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. CWMCapOvrvw.PDF | |
| CWM Comprehensive Die Casting Capabilities Brochure | |
| 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. CWM General Brochure.pdf | |
| CWM Al, Mg & Zn Die Cast Production Specs | |
| 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. AlloySpecGd.pdf | |
| Design & Specification Guide for Custom Die Castings | |
| 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. Die-Casting-Design-Specification-Guide-2017.pdf | |
Environmental
| EPA-Compliant Chromate for Al, Mg & Zn Parts | |
| 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. TriChrmTB.pdf | |
| NADCA: For Efficient Manufacturing, Look to Die Casting | |
| 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. NADCAEffctMfg-DC.PDF | |
| The Plastic vs Die Casting Process Decision | |
| 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 MgBenefitsTB.pdf | |
| Designing for Servicing & Recyclability | |
| 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. NADCAProdRcycl.PDF | |
Metal Flow Simulation
| Die Casting Design & Production Preplanning Guide | |
| 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. Dsn_ProdPreplnGd.pdf | |
| Overview of CWM Die Casting & Production Capabilities | |
| 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. CWMCapOvrvw.PDF | |
| CWM Comprehensive Die Casting Capabilities Brochure | |
| 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. CWM General Brochure.pdf | |
| CWM Al, Mg & Zn Die Cast Production Specs | |
| 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. AlloySpecGd.pdf | |
| 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 | |
| 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 | |
| How Magmasoft Process Simulation Lowers Costs | |
| 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. MgmaSftTB.PDF | |
| Magnesium EMI Shielding Characteristics | |
| 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. MG_EMI_Shield.PDF | |
| NADCA: Comparison of Mag Die Casting & Plastic Parts | |
| 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. NADCAMg2Plstc.pdf | |
| Product Solutions Through 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. DieCastingProdSols.mp4 | |
Sourcing
| The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S | |
| 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.” InsrcBoomTB.PDF | |
| USA Today: Manufacturing Heading Back to USA? | |
| 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, MfgBck2USTB.PDF | |
| Leveraging DFM Prior to Design Commitment | |
| 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. 3CWM_Webinars/CWM_Webinar3/player.php | |
| Machining to Die Casting: A Guide to Conversion | |
| 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. MCDCWebinar5.mp4 | |
| Book Review: "Poorly Made in China" | |
| 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.
PrlyMdChnaTB.pdf | |
| Product Solutions Through 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. DieCastingProdSols.mp4 | |
| Design News Engrg Survey & Key DC2 OEM Resources | |
| 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. SlryGains-DCKnowlTB.PDF | |
| Surface Finishes 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. SurfaceFinishesForDieCasting2015.mp4 | |
| Die Cast Design Myths Can Cripple Optimum Decisions | |
| 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. Dsn_Prod_Myths.pdf | |
| The Die Casting Process: An OEM Designer's Overview | |
| 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. 3CWM_Webinars/CWM_Webinar1/player.php | |
| Die Casting Spec & Sourcing Aids for OEM Buyers | |
| 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. OEMBuyrSrcTool.pdf |  |
| The Miniature Zinc Die Casting Advantage | |
| 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. MDCAdvantage.mp4 | |
| Hidden Costs of Sourcing Die Castings Offshore | |
| 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. HiddenCstsOffshr-Byr.PDF | |
| 10 Ways to Reduce the Costs of Die Cast 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. 10Ways.PDF | |
| How to Select the Best Custom Die Caster | |
| 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. SelBstDCtb.pdf | |
| Die Casting Design & Production Preplanning Guide | |
| 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. Dsn_ProdPreplnGd.pdf | |
| Magnesium EMI Shielding Characteristics | |
| 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. MG_EMI_Shield.PDF | |
| CWM Al, Mg & Zn Die Cast Production Specs | |
| 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. AlloySpecGd.pdf | |
| NADCA Collaborative Engineering White Paper | |
| In-depth White Paper from the North American Die Casting Assn. details 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. NADCA.Coll.Engr.pdf | |
| NADCA Collaborative Engineering White Paper | |
| This in-depth White Paper from the North American Die Casting Assn. 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. NADCA.Coll.Engr.pdf | |
| NADCA Commercial Practices for Die Casting Buyers | |
| 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. 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. NADCACommlBuyPract.pdf | |
| Design & Specification Guide for Custom Die Castings | |
| 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. Die-Casting-Design-Specification-Guide-2017.pdf | |
| NADCA: Comparison of Mag Die Casting & Plastic Parts | |
| 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. NADCAMg2Plstc.pdf | |
| NADCA: Die Cast Production & Finishing Checklists | |
| 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) NADCAFshngChklst.PDF | |
| NADCA: For Efficient Manufacturing, Look to Die Casting | |
| 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. NADCAEffctMfg-DC.PDF | |
EMI Shielding
| The Plastic vs Die Casting Process Decision | |
| 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 MgBenefitsTB.pdf | |
| Tutorial: Electronic Enclosure Design for Die Casting | |
| 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. NADCA.EnclDsn.pdf | |
| Die Cast Zn for Key Computer Structural Component | |
| 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. ZnKeyStructure.PDF | |
| 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 | |
| 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 | |
| NADCA Standards: Aluminum Alloy Data | |
| Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCA_Al_Alloy.pdf | |
| NADCA Standards: Magnesium Alloy Data | |
| Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCA_Mg_Alloy.pdf | |
| NADCA Standards: Zinc & ZA Alloy Data | |
| Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. NADCAZnAllyData.pdf | |
| Superior EMI Shielding with Die Cast Housings | |
| 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. EMIShld4Hsgs.PDF | |
Reshoring
| Book Review: "Poorly Made in China" | |
| 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.
PrlyMdChnaTB.pdf | |
| Hidden Costs of Sourcing Die Castings Offshore | |
| 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. HiddenCstsOffshr-Byr.PDF | |
| The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S | |
| 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.” InsrcBoomTB.PDF | |
| USA Today: Manufacturing Heading Back to USA? | |
| 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, MfgBck2USTB.PDF | |
| Rising Wages, Acknowledgment of Hidden Costs Bring Manufacturing Back to U.S. Shores | |
| 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. NADCAHidCstsOffShr.pdf |  |
| U.S. Manufacturing… Pain & Promise | |
| A 2 page NADCA report on US jobs and outsourcing. Reviews US job loss and potential return. USMfgPn_Prms.pdf |  |
