Aluminum Die Casting

Industry Outlook

Due to the increasing popularity of automation, the robotics industry continues an upward trend in today’s economy.  Robots take necessary operations and create measurable tasks, which can accurately estimate project timelines.  Robots also perform tasks at a lower cost and allow very little room for error, working in a way that cannot be replicated by a human manufacturing team.  New robot technology is constantly being researched and implemented, allowing rapid growth in capabilities.  Though the robotics industry is generally known for great success in automotive manufacturing, it has given various other industries the benefits of automation.

For example, service robotics are being utilized in government initiatives for military/defense sectors to reduce human involvement.  This would increase the number of unmanned ground vehicles deployed into the front lines, reducing the number of casualties in the face of danger.

The medical industry is another example.  Medical service robots work with MRI, CT scans, fluoroscopy and ultrasound imaging, increasing productivity and decreasing malpractice liability, human error, and the exposure of radiation to human staff.

Service robotics are estimated to reach $21.7 billion by 2022, with growth over 17.8% from 2015 to 2022.  Medical service robotics sales were just over $2.1 billion in 2014 and are expected to exceed $6 billion by 2022, growing 15% during the forecast period.

The Role of Die Casting in Robotics Products

There are many parts inside of a robot which are ideal candidates for the die casting process.  Aluminum, magnesium, and zinc are the most common alloys in die casting and all three can be used in any type of robotic equipment based on part requirements.  CWM die casts durable components that withstand the wear of repeated tasks, exposure to harsh environments as well as office settings, and protect the delicate electrical work in a robot.

How CWM Contributed Die Castings to the Industry

Chicago White Metal manufactures thousands of parts that have been incorporated into robots.  The CWM engineering team collaborates with customers to produce castings at reduced costs.  These parts are generally high in quality and in strength to protect the delicate electrical work in a robot.

Aluminum for Robotics

Aluminum A380 is the most frequently used alloy in die casting, offering the best combination of material properties and castability.  Aluminum die castings are used in various industries, including the robotics industry.  CWM casts several components, including housing in the arm, wrist, base, “elbow”, and several other parts of industrial robots.  CWM offers an aluminum alloy data sheet, available for download here.

Aluminum is the ideal choice when the strength-weight ratio is important.  It is about 1/3 the weight of steel and higher tensile strength than cast iron, which are other popular metals used in robot manufacturing.  Of the three, aluminum is the most abundant resource, providing a cost-efficient product.  Aluminum is also an excellent non-magnetic, non-sparking conductor, which makes it suitable for robotic construction.

Magnesium in the future?

Magnesium AZ91D is known for its lightweight properties as a metal.  AZ91D can also be designed for robotic components, when the requirements call for a weight reduction and portability without compromising on material strength and rigidity.  Chicago White Metal can use magnesium in various robotic applications.  For more information on the Magnesium alloy AZ91D, download the white paper here.

If you would like to learn more about the capabilities of die casting and the robotics industry, e-mail us at sales@cwmtl.com or give us a call at 630-595-4424.

Industry Outlook

The lawn and garden power equipment industry is experiencing a steady increase each year, with a 3.2% annual growth rate.  Projections show that at this rate, the industry will reach $11.7 billion by 2019.  While the residential consumer segment still dominates the market, the commercial market has seen an uptick in growth that is clearly outpacing the segment.

The lawn and garden industry includes products such as lawnmowers, turf and grounds equipment, trimmers, edgers, garden tractors, rotary tillers, chainsaws, blowers, vacuums, pruners, sweepers, snow throwers, hedge trimmers, and many other power equipment items.  There is a growing importance within the industry not only for performance, portability, affordability and quality, but also to incorporate environmentally-friendly processes to the manufacturing and assembly of the internal parts of the equipment and machinery.

The Role of Die Casting in Lawn & Garden Products

There are hundreds of components within lawn and garden equipment and vehicles which are ideal candidates for the die casting process.  Aluminum, magnesium and zinc are the most common alloys in die casting and all three are used in a variety of lawn and garden product applications where they provide better overall value than plastic, stampings or machined parts.  Each of the die cast alloys have unique properties that can be used based on the requirements for the parts.  CWM die casts components in all three alloys to meet the durability and high strength demands for outdoor, rugged and long-lasting end products.

How CWM Contributed Die Castings to the Industry 

Chicago White Metal manufactures hundreds of thousands of parts which have made their way into various consumer and commercial applications within the industry.  The CWM Engineering team works with customers to engineer and produce durable, high quality parts at reduced costs.

Aluminum for Encasements

Aluminum A380 is by far the most frequently used alloy in die casting.  This alloy offers the best combination of material properties and castability.  Aluminum alloy die castings are used in a wide variety of industries, including the lawn and garden industry.  CWM casts several components, including gear cases, covers, and several parts which go into a differential assembly. 

Magnesium for Portability

Magnesium AZ91D is the material incorporated into the design of several components for portability because of the alloy’s lightweight properties – a known alternative to plastic but with the strength and rigidity of a metal.  Chicago White Metal uses magnesium to cast parts that are ultimately assembled in lawn and garden end products, including both consumer and professional handheld lawn maintenance equipment.  This bearing cap is part of an assembly inside of a professional hedge trimmer & blower.

Various roll cages have also been produced by CWM, which go into differentials found in commercial and consumer mowers.  Along with the examples given, many other components have been engineered and manufactured by our team to carefully meet the high standards of our customers within the lawn and garden industry.

If you would like to learn more about the capabilities of die casting and the lawn and garden industry, e-mail us at sales@cwmtl.com or give us a call at 630-595-4424.

One of CWM’s Sales Engineers coined the phrase, ‘Start with the finish in mind.’   This is because the specific design features of a die cast part, in almost every case, has a direct impact on achieving the required surface finish specifications. For this reason, all die casting finishing requirements should be discussed with the die caster early in the design phase.

Die castings and subsequent surface finishes have a symbiotic relationship. That is, the results of each process “work together,” and each benefit from the relationship. For example, aluminum die castings that call for a cosmetic surface will require attention to the location of the casting’s parting line, gate, overflows and vents. If these design features interfere with or blemish any of the part’s designated cosmetic surfaces, undesired results will occur.

The importance of reviewing the finish with the die caster early in the project is also exemplified by the tool design. Cosmetic surface requirements for the custom die casting may require special finishing of the cavities of the die. In addition, the cover die half will generally be used to produce a specified cosmetic surface. This permits the ejector die half to contain the required ejector pins— which assist in ejecting the part cleanly from the die.

It is essential that the die caster understands how parts mate with other components in the final product assembly. The die caster will analyze the design to assure a quality finish, and equally important, to make sure that tolerance specifications will be met. If this step is omitted, it could lead to additional finishing processes that increase piece price costs.

Cost is certainly another driver to have an early discussion with the potential die cast supplier. As discussed earlier, the geometry of the design’s features have a direct impact on the final surface finish. An early review with the die caster can result in minor modifications (i.e., critical surfaces, edges, and mounting features) that reduce the need for surface preparation before the final coating. The end result is increased efficiency which has a direct impact on lowering the final production cost.

Unlike many die casters that only produce raw castings, CWM is a full-service, die cast-to-finish supplier. Over 90% of our castings include additional post-cast finishing operations prior to shipment to our customers. With that high volume of post-finishing experience, coupled with over 75 years of performance, our die cast finishing expertise is unsurpassed. Further, when it comes to recommending the right alloy with the optimal finishing process, CWM is in a unique position to provide unbiased information since we work with the most widely used metals: aluminum, magnesium and zinc. If you would like to tap in to that experience by reviewing your project with a CWM Sales Engineer, please call us at 630-595-4424.

CWM Wins NADCA 2012 Aluminum Die Casting Award

Key aluminum handle riser component for the new compound bow developed for young archers by industry leader Bowtech, produced as a high-tech die casting by Chicago White Metal Casting, won the 2012 NADCA International Die Casting Competition in the under one lb. classification.

Specifications called for the aluminum die cast riser to meet exacting professional bow tolerances at a targeted marketing price, plus conformance to a machined “hogout” appearance with all evidence of casting gates absent.

Download the Case Study of this riser die casting, in the Case Study section of the OEM Die Cast Design Center.