Comparing Aluminum, Magnesium, and Zinc Alloys

Aluminum, Magnesium, and Zinc are the most common alloys used in the die casting process. But how much do we really know about these alloys? To start, Aluminum and Magnesium are “lightweight” metals, while Zinc alloys provide higher precision and longer tool life.

If you are at the point where you’re considering die casting for your project, the next step is determining which alloy is best suited for a specific application of your part. That’s typically based on the design specifications – as the alloy provides the physical and mechanical properties that are required by the end product application. Therefore, you need to seek a die casting supplier that understands each type of alloy offered and what benefits are involved so they can lead you in the right direction.

Aluminum Die Cast Alloy

Aluminum is easily the most frequently used metal in die casting. The most common Aluminum die casting alloy is A380 because it offers the best combination of material properties and castability. Aluminum alloy die castings are used in a wide variety of industries. It is common to see this alloy in electronics, communications equipment, automotive components, lawnmower housings, and many other products.

Aluminum Die Casting

Aluminum alloys for die casting have superior machining characteristics, especially when compared to iron, steel, and titanium.

Magnesium Die Cast Alloy

Magnesium alloys are very light but still offer high levels of strength. Magnesium alloy AZ91D is the strongest and most castable of the commercial Magnesium die casting alloys available, and it is also the most widely used for that reason.

AZ91D Magnesium is a high purity die casting alloy which provides the following qualities:

Magnesium Die Casting
  • Good Corrosion Resistance
  • Excellent Castability
  • Superb Strength
  • Lightweight (1/3 less weight than aluminum)
  • Longer tool life (perhaps 3X that of aluminum)

Corrosion resistance is achieved by enforcing strict limits on three metallic impurities: Iron, Nickel, and Copper. While there are special precautions to take when machining or grinding Magnesium die castings, Magnesium alloys machine easily, requiring less power to machine than the other die casting alloys.

Magnesium’s durable properties and lightweight make it an ideal alloy for the automotive industry. Magnesium die castings are also used for electronic casing and housings, and more recently, it’s become popular in the aerospace industry.

Zinc Die Casting Alloys

CWM casts two different Zinc alloys: Zamak #3 and ZA-8. Both offer the ability to cast with intricate detail and close dimensional tolerances at high production rates. The first Zinc alloy, ZAMAK #3, contains approximately 4% Aluminum and a smaller percentage of Magnesium to achieve strength, hardness, and corrosion resistance properties. The second, ZA-8, has approximately 8% Aluminum and less copper content. It offers higher strength, superior wear resistance, superior creep resistance, and slighly lower density.

Mini Zinc Die Casting

Zinc alloys are commonly used for smaller die castings or die castings that require thinner sections. This is because Zinc alloys have superb castability, generally allow more significant variation in section thickness and can maintain closer tolerances. Also, the impact strength of Zinc die cast components is higher than the other common metal alloys and zinc provided the longest tool life of any die cast alloy. That makes zinc ideal for the automotive industry and numerous other small customized industrial parts.

The CWM Difference

At Chicago White Metal Casting, we custom produce Aluminum, Magnesium, Zinc, and Miniature Zinc die castings. Our experienced sales and engineering teams will work with your company from start to finish to deliver high-quality castings that meet even the highest standards.

Contact us here if you think your project could be a good fit for Aluminum, Magnesium, or Zinc die casting. You can also request a quote on this page.

Equipment Highlight: CWM’s new 1000-Ton Die Casting Machine

In September of 2020, Chicago White Metal’s maintenance team took on the task of installing a brand new aluminum 1000-ton die casting machine. Under the leadership of Max Golovin, CWM’s Director of R&D, the installation of a new IDRA-900 Xpress Die Casting Machine was completed in the spring of 2021. CWM produced the first official casting from the new machine on March 24, 2021.

The purchase of the IDRA Xpress 900 Series Die Casting Machine gives CWM the ability to expand our already extensive capabilities. Bill Erbacci, CWM’s Customer Care/Fulfillment Manager, said, “The new IDRA machine gives CWM increased capacity and scheduling flexibility. As a result, CWM can run a broader mix of parts in the new IDRA. This translates into shorter die casting lead times for our customer’s orders.”

Benefits of the IDRA Xpress 900

The IDRA Xpress 900 Series Die Casting Machine features a state-of-the-art design with a 900 Metric (1000 US) ton clamping force capacity and a larger platen than other CWM machines. In addition, the Xpress Series from IDRA offers a Rigid Toggle System, which gives the machine the closing force necessary to produce larger, thin wall, complex parts.

The Xpress Series from IDRA was an ideal choice for CWM because it offers excellent efficiency and long-lasting precision – it also provides:

  • Fast and reliable injection of the molten metal
  • Longevity, because it’s built to last in heavy-duty conditions
  • Easy maintenance
  • Low energy consumption
  • Full automation

One of the most significant benefits of adding the IDRA Xpress 900 Series Die Casting Cell to CWM’s fleet of equipment is that it is a complete Die Casting Cell. Meaning, it’s equipped with its own melting furnace, two robots, an automatic sprayer, hot-oil heating units, water-cooling system, part cooling conveyor, and trim press. One robot loads ingots into the furnace, while the other extracts the part from the die and places it on the conveyer.

What the Future Holds

CWM has already produced many parts in the new machine, and the results have been excellent. The IDRA Xpress 900 Series Die Casting Machine allows CWM to push the boundaries because we can now produce larger parts while still maintaining the highest quality possible.

Contact the CWM Team today if you or your team have a part that you think might be a good fit for CWM’s high pressure die casting process. Click here to visit our contact page or fill out a quote request.

Preparing for Installation

After installation:

How to Select the Right Die Caster

When you’ve designed a part and are ready to partner with a die caster, you need to know that you’re working with the best. Unfortunately, unless you have an existing relationship with a reputable die casting supplier already established, finding the right partner to cast your part can be difficult.

When choosing a die caster, whether for aluminum, magnesium, or zinc die cast metals, most believe it simply comes down to cost. While cost carries a great deal of weight in the decision-making process, a good die caster will offer much more than a competitive price. They’ll provide you with a full range of services and post-production capabilities that can save you time and money in the long run.

Services like design engineering, mold flow simulation, and a wide variety of post-casting processes such as CNC machining, deburring, painting, plating, assembly, and total quality management, can sometimes be overlooked, but these services can prove very valuable. So when you work with a full-service die caster, make sure that these additional services and operations are part of the quote – that way, there are no surprises when you’re ready to move forward with the production of your part.

Benefits of working with a Full-Service Die Caster

Choosing to go with a single full-service die caster versus managing multiple processes and vendors on your own helps free up your company’s resources, decrease lead times, streamline logistics and inventory management, and saves money. In addition, it can result in improved designs and lower total cost because the full-service die caster will look for ways to add value across all of the processes.  

Before building a tool for your metal die casting design, be sure that your engineering team and the die caster are on the same page. At Chicago White Metal, our die casting engineers will engage with you to fully understand your product, its cosmetic and performance requirements, and its intended environment. With that understanding, our engineers can help optimize your design for maximum performance and overall value. In addition, the die casting engineer’s preplanning and analysis can recommend cost-saving measures — or prevent costly mistakes over the project life.

Another important question to ask during this process is whether or not the die casting supplier utilizes advanced technology such as process simulation software (e.g., Magmasoft®) before the tool is built? Using your CAD file, CWM can use the software to predict and optimize metal flow, air entrapment, metal velocity, thermal balance, hotspots, etc., during the die casting process. This will assure a quality die casting design, shorten lead times, and lower production costs.

Trust is the Name of the Game

The final question that your team should ask before choosing a die casting partner is whether or not you can trust that they will be there for you and your team throughout the process to produce the best possible part. Many factors contribute to the success of your project. Even the alloy choice (CWM offers aluminum, zinc, and magnesium) is an important decision because each has its unique properties with advantages and disadvantages. If your product requires post-finishing, it’s even more important to choose the right alloy because the physical properties of each alloy may or may not work with each type of finish.

While alloy recommendation is crucial for the success of your project, finishing options are equally important. It’s vital to ensure that your die casting supplier understands all the finishing options available and can guide you to the right finish. The die casting engineer must know all these variables from the project onset, avoiding costly quality issues later. These are things that our team at CWM takes into consideration with every project.

Experience matters, and with 84 years of experience and counting, CWM sets the industry standard for excellence. If you have any questions about the high-pressure die casting process, don’t hesitate to contact Chicago White Metal today. One of our experienced team members will be happy to help guide you in the right direction!

Equipment Highlight: FANUC Robots

Benefits of using Robots

At Chicago White Metal Casting, we strive to have the most advanced technologies available to assist with die casting, CNC machining, and other operations. For example, CWM has two FANUC robots in our CNC department – the M10iA and the M-20iB. The M-10/20 series robots offer increased load capacity and extended reach. These robots are small, but they are the perfect automation solution for many applications, especially when it comes to handling, assembly, material removal, and machine tending.

In addition to its increased load capacity and reach, the M-10/20 series robots use considerably less energy than older models; they also boast a cost-efficient modular design. Furthermore, the M-10/20 series robots offer integrated cable routing, making them considerably easier to maintain – ultimately saving time and money.

Robot Use at CWM

At CWM, we use the FANUC M-10/20 series robots to load/unload the CNC machining center for some of CWM’s higher volume parts. The robots that CWM employs can work with several different part numbers and utilizes camera-based vision systems to accomplish the following:

  • Verify the presence and location of holes
  • Determine the orientation of the part
  • Load and unload parts onto a CNC fixture
  • Install special clamping inserts
  • Confirm the clamping is correct
  • Sequence part unloading/loading from conveyor

One of the most significant advantages of utilizing these robots is that several hours’ worth of material can be loaded/unloaded into side-by-side input/output conveyors integrated into the cell and tied into the robot’s logic. This system allows the robot/CNC cell to work continuously, resulting in a steady flow of parts. In addition, the robot incorporates several camera-based inspection steps using a 2D vision verification system that stimulates the eyes, further assuring that parts will meet CWM’s and the customer’s quality standards.

FANUC M-10iA Robot.

Camera to confirm part integrity.

Loading conveyer.

Unloading conveyer.

CNC machine where the part is loaded.

Why Did CWM Choose FANUC?

The FANUC M-10/20 robots are designed for various light material handling applications. They are considered high-speed robots and can be used in many scenarios, including assembly, CNC machine tending, and even in the die casting process. In addition, this robot simplifies applications and floor plans because it is more compact than other robots while maintaining the highest axis speeds and best repeatability. 

Another benefit of using these robots is they can be mounted at any angle on the floor, wall, or ceiling. They are also very small, which means they can fit into tight workspaces. At Chicago White Metal, we currently have six active robots in our CNC department – four universal co-bots and two FANUC Robot Cells. Co-bots, or collaborative robots, are different from robots because they can work with humans to accomplish tasks while robots work independently and run with no human intervention.

To learn more about the equipment that we have here at CWM, visit this page. If you would like to contact our team here at CWM, call (630) 595-4424, or you can request a quote here.

Electric Vehicles: Component Manufacturing Using the High-Pressure Die Casting Process

The automobile industry is the largest market for high pressure die casting components. The demand for electric vehicles has been rapidly growing thanks in large part to changes in emission norms worldwide and a shift in consumer preferences. These changes have pushed automakers to replace heavier components with lightweight, environmentally-friendly options made from alloys like Magnesium or Aluminum.

Reducing weight is significant for hybrid electric, plug-in hybrid electric, and electric vehicles, where battery efficiency is critical. Aluminum and Magnesium die cast components can dramatically reduce vehicle weight, which improves overall vehicle performance, increases fuel or battery efficiency, and extends driving range. Chicago White Metal is helping to fuel this evolution by casting complex shapes at near-net shape in high volumes and within tight tolerances using lightweight alloys.

Aluminum

Automakers who make electric or hybrid cars are increasingly turning to Aluminum due to its combination of excellent mechanical and physical properties at an attractive cost. In addition to weight reduction, high-pressure die cast aluminum alloys have added dimensional accuracy and stability – not to mention the added strength and high-speed production capabilities.

Lighter Weight and Good Malleability

While not as light as Magnesium, Aluminum is still 1/3 the weight of steel, which goes a long way when it comes to reducing the weight of a vehicle. That’s why Aluminum die castings are replacing steel in structural and cosmetic body parts (i.e., vehicle bodies, hoods, doors, bumpers, crash boxes) in modern vehicles.

Malleability is also a significant factor as to why automakers are turning to Aluminum. It can be easily rolled into a sheet, formed as a stamping or extrusion, or welded. And it can be a high-pressure die cast, which allows for the rapid conversion of molten metal to a net shape 3-dimensional complex shape.

Aluminum is excellent for automotive applications when there’s a need for high visibility and structural integrity, such as in A-B-C pillars. While Aluminum is lighter than steel, it absorbs more energy, providing an extra layer of safety for the vehicle as well. Utilizing aluminum components can help reduce vehicle weight by as much as 40% without compromising the safety of the vehicle.

Magnesium

Magnesium was initially used in race cars in the 1920s to gain a competitive edge because of how lightweight it is. Now automakers use this lightweight alloy for applications like mirror housings, steering columns, driver’s airbag casings, seat frames, and dash encasings.

The auto industry’s quest for greater battery and fuel efficiency, along with demand for improved performance, has driven an increased interest in high-pressure die cast Magnesium alloys. These alloys include AZ91D with its excellent combination of mechanical properties and the highest strength to weight ratio of any structural metal.

Mg is 75% Lighter than Steel, 33% Lighter than Aluminum 

Magnesium provides a drastic weight difference that supports its use as a durable metal alternative to steel and plastic. Unlike plastic, Magnesium’s properties do not degrade with temperature and UV light, and Magnesium is 100% recyclable. With its superior dampening capacity and low-mass inertia, Magnesium is well suited for parts designed for frequent and sudden changes in motion direction – making it ideal for car part design. Many part designers also prefer working with Magnesium because they can produce parts that are more complex than steel, without sacrificing strength.

Zinc

Although Zinc products are heavier than their Aluminum and Magnesium-based counterparts, they do have the highest yield strength of all three alloys. Zinc can also be cast thinner than any other metal and can hold extremely tight tolerance requirements. While Zinc might not be the best option when it comes to the light-weighting strategy, several Zinc-made applications are ideal for automotive design and structure.

The CWM Difference

Chicago White Metal Casting can cast all three families of alloys; Aluminum, Magnesium, and Zinc. Our technical expertise, combined with full-service capabilities and engineer design services, can provide automakers or part designers with die casting solutions that meet the challenges of their hybrid electric, plug-in hybrid electric, and electric vehicle part design.

Contact us today by filling out the form on this page or call +1 630-595-4424 to speak with a member of our team.

Click here to download the White Paper .PDF.

Die Cast Prototyping – Benefits and Types

In addition to Chicago White Metal’s advanced part design and DFM assistance, CWM offers various prototyping options to bridge the gap between design and production tooled high pressure die casting. CWM’s prototyping process offerings include:

  • 3D printing (resin)
  • CNC machining
  • Gravity casting via the sand, rubber-plaster mold, or investment casting processes
  • Prototype die casting

Reasons to Use Prototyping

Prototyping offers the opportunity for design verification – a chance to identify design flaws before committing to production level tooling. And while it is not necessary to prototype every design, sometimes doing so saves time and money. Generally, the further along in the developmental cycle a design error is discovered, the greater its cost.

When tooling needs to be scrapped or reworked, the impact is evident in terms of costs and delays. However, reworking a die cast die also adds cost in decreased die life and potential negative quality impacts. Using today’s prototyping technologies can help manufacturers avoid these stressful situations.

There are several prototype methods from which to choose. Selecting the best option for your application comes down to tradeoffs. For example, some options, such as 3D printing of a plastic model or machining from billet, are relatively inexpensive for low quantities because no tooling is required. But the mechanical properties of a plastic or machined part are quite different than the properties of a die casting. Assessing what prototype process is best for your needs requires consideration of quantity, timing, mechanical properties, dimensional accuracy, surface finish, wall thickness, cosmetic requirements, etc. A good high pressure die casting supplier should be able to guide you toward the appropriate option.

Prototype Methods

(click image to enlarge)

3D Printed Prototypes

3D printing enables the production of rapid prototypes in many types of plastic, directly from STL design files. Fused Deposit Modeling (FDM) is one form of 3D printing that builds parts layer-by-layer, from resin, directly from 3D computer data. An FDM machine can produce geometrically complex shapes to tolerances of +0.005 in (+.127 mm).

At CWM, we use FDM prototypes for every new die casting project to expedite production and shorten total lead-times. These prototypes give our suppliers and our engineering, production, and quality teams a chance to see parts in advance, ensuring that the part and die cast design is robust. They are also used to develop fixtures, tools, racks, etc., for inspection, machining, assembly, painting, plating, etc. FDM models ensure that the part design results in an efficient manufacturing process and helps reduce overall project lead-time by allowing simultaneous construction of downstream process tooling.

Machined Prototypes

Machined prototypes are widely used because they offer product designers a good combination of physical and mechanical properties, generally short lead-time, and zero to minimal tooling investment. Prototype parts can be machined from billet via CNC machining by working directly from customer CAD files. After transferring a machined prototype to a CAM program interfacing with CNC workstations, we can produce these prototypes in just a couple of days.

CNC machining can produce parts to almost identical part weights and hold exceptional tolerances such that validation of form and fit is assured; we can then perform many functional tests. However, properties are not identical to die castings and parting line conditions, and sometimes the draft required in a die casting is not represented in a machined prototype.

Gravity Cast Prototypes

Sand casting, investment casting, and rubber plaster-mold castings are some of the gravity cast processes used for prototyping. Because of longer solidification times and alloys specific to those processes, various heat treatments are used to approximate a high pressure die casting alloy’s properties.

Compared to high-pressure die casting, sand cast prototypes require thicker walls and larger tolerances, so features that might be “as-cast” in a die casting may need to be machined in a sand casting. These processes utilize lower-cost tooling than high-pressure die casting but have much higher piece prices. These design, property, and cost tradeoffs have to be considered when evaluating the best prototype approach.

Die Cast Prototypes

For those who want a prototype with the same properties, alloy, and geometry designated for production and larger quantities, a high pressure die cast prototype is often the best approach. Prototype die casting dies can be produced in shorter lead-times and at less cost because they utilize standardized components – like an existing die base – and pre-hardened, uncoated tool steels that do not require post machining heat treatment.

The tool will not run as efficiently as a typical production die, and flash will need to be removed by hand instead of with a production trim die, but part costs will be much less than machined or gravity cast prototypes. A prototype tool can provide 1000 or more high-quality pieces that can be used for prototype or even initial production.  

The CWM Difference

Chicago White Metal offers all of these prototype options that you read about today. If you are interested in more information about prototyping or if you would like to speak with one of our team members, email sales@cwmtl.com or call (630) 595-4424.

Aluminum Die Casting Benefits & Die Life Considerations

If you are considering aluminum die casting for a new part, there are several advantages to doing so. Aluminum die castings are lightweight, corrosion-resistant, has high thermal and electrical conductivity, and are very durable. Aluminum die castings remain strong at high temperatures and retain their dimensional stability even if the part has thin walls or is a complex shape.

Aluminum die castings also have excellent mechanical properties, making it a popular alternative to steel and iron. This is especially true for the automotive industry, which is continually looking for lightweight, durable materials.

Benefits of Aluminum Die Casting

Aluminum can be cast in a variety of ways. The benefit of using the high pressure die casting process over other aluminum casting processes is lower part cost. The aluminum high-pressure die casting process can produce a near-net shape in seconds.

Though high pressure die casting tooling is more expensive than other casting processes, the heat-treated steel and water-cooled die cast die might produce 75K-200K “shots” over its life. And depending upon the part size, geometry, and demand, tools can often be built to produce multiple parts in one “shot,” which further reduces the part price and allows the tooling cost to be amortized over very large quantities of parts.  

Aluminum is the most popular die casting material by far because it is economical and provides a good mix of properties. There are a surprising amount of parts from numerous industries – like automotive, medical, alternative energy – that are cast via the aluminum die casting process due to its many valuable properties.

Aluminum Die Casting and Die Life Considerations

To maximize die life, certain considerations must be taken into account before building the die. Factors that contribute to die life include:

  • The overall design of the part
  • Type of tool used to create the die
  • Configuration of the mold
  • Die steel, heat-treating techniques, and die coatings
  • Expectation for part quality

Before a die is built, the customer first presents a concept or existing part to a die caster. A die cast engineer will assess the project from design to end product and work with the customer to optimize the part design for die casting. An initial discussion with the die caster may include topics such as:

  • Functional and cosmetic requirements
  • Tolerances
  • Annual and lifetime volume
  • Alloy choice
  • Mating parts
  • Project timing
  • Optimizing wall thickness

Importance of Partnering with an Experienced Die Caster

An experienced die caster will take the time to consult with you about your application and assist you with product design. They will then design the tooling to produce parts with repeatable dimensions, excellent surface quality, consistent mechanical properties, and long tool life.  

These factors provide the greatest opportunity for cost savings and maximizing value. A less experienced die caster might offer lower initial costs, but this could cost you in the long run, due to quality, delivery, or tool life issues. A die built to lower specifications will likely fail at an inopportune moment, shutting down production and forcing you to spend much more than what you thought you saved initially.

Contact Chicago White Metal Today

Chicago White Metal Casting (CWM) has 83 years of experience providing our customers with excellent service, saving you money, and resulting in products that you and your customers will love. To find out more about our aluminum die casting service, or other capabilities, contact us online today. You can also reach us at +1 630-595-4425 or via email (sales@cwmtl.com) if you have any questions. You can also click here to request a quote online.

CWM Adds New Idra Die Casting Machine, Full Implementation Planned for Q4 of 2020

Chicago White Metal is extremely proactive in the research of advanced technology and innovation, and their implementation into the die casting process. These efforts are put forth by the company in order to improve and enhance quality, efficiency, measurability, and overall cost savings for existing and future projects.

CWM leadership encourages an environment of cultivating innovative ideas where process improvement is concerned, granting members of the team an opportunity to take an active role in examining and suggesting alternatives to either modify or drastically change current techniques. The team is excited to implement these innovations into the workflow in both traditional and non-traditional ways. 

New Idra Die Casting Machine (2019)

A new Idra Die Casting machine was purchased last year. Extensive planning by the Chicago White Metal team was thoughtfully executed, with full implementation planned for the beginning of Q4 in 2020. This new die casting machine has a 900-ton capacity, which gives Chicago White Metal the opportunity to accommodate substantially larger applications. Although the machine is being installed into the magnesium department, it will initially be used to cast aluminum parts. 

CWM Takes Recycling to New Levels

CWM Recycles AL, ZN, and MG
CWM Recycles

As a further refinement to our environmentally responsible culture, CWM has launched a new Recycling Initiative to help take our focus on environmentally friendly manufacturing and overall stewardship to a new level. One of our key objectives is to encourage similar programs with our suppliers, neighbors, and customers.

CWM Recycles Magnesium Scrap

CWM’s recycled materials, such as plastic, steel, cardboard, electronics, etc. are typically sent to a certified recycling vendor. CWM, however, as part of our new Recycling Initiative, is taking the extraordinary step of requiring our recycling vendors to provide a full manifest/certification and/or a detailed process map that illustrates exactly how recyclables are processed. We are finding that not everything is being recycled as we thought. Plans are underway to deal with this issue transparently, and to determine what improvements can be made.

We are also asking our suppliers to provide the recycled content of products sold to CWM. As an example, we asked our food/beverage provider to see if plastic stirrers, lids, utensils, and containers can be replaced with something more environmentally friendly. That effort resulted in eliminating plastic soda bottles (cans and cartons only), changing coffee stirrers from plastic to wood, and replacing foam coffee cups with biodegradable ones.

CWM takes environmental stewardship seriously. We’ve been a leader in our industry in this regard, having had recycling programs in place for more than 30 years. And though we can’t completely overhaul the entire recycling industry on our own, our team will do what we can to initiate changes. We are confident that this renewed Recycling Initiative will have a very positive impact on CWM and our community of suppliers, customers, and neighbors. Stay tuned for more information in the coming months!

CWM and Crossbow Manufacturer Hit the Target with a NADCA Design Award!

CWM CEO and President Eric Treiber accepts NADCA Award
CWM CEO and President Eric Treiber accepts NADCA Award

Chicago White Metal collaborated with a crossbow maker to get a bullseye win for a riser part!  Eric Treiber accepted the award on behalf of CWM for the 2018 North American Die Casting Association (NADCA) Excellence in Design Award, winning the “Aluminum 1 to 10 lbs.” category.

The crossbow manufacturing company was focused primarily on two things: safety and quality.  The riser is a safety-critical part that is the “heart” of the crossbow, so the strength of the part was vital to the success of the end product.  The crossbow was designed to be narrow and made for pinpoint accuracy.  It is one of the lightest crossbows on the market, weighing in at only 6.3 lbs.

Crossbow riser piece cast by CWM

This was the manufacturer’s very first die cast part, which enabled them to convert the “machined from extrusion” approach that they typically do for crossbow risers to a high pressure die casting process.  The design was modified to incorporate as-cast pockets in order to eliminate additional assembly.  Ultimately, the cost was reduced by 1/3 simply by converting to the high-pressure die casting process.

“The Aluminum 1 to 10 lbs category is typically a more competitive category.  That makes the win even more of an honor,” Marketing Coordinator Roseann Rimocal says.

CWM’s internal marketing showcase will display the parts, the end product, and the award for a couple weeks.  The plaque will then be transferred to its new home in the Research & Development wing, along with a number of other design awards Chicago White Metal has taken home over the course of many years.