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Case Studies

Innovative Solutions for Complex Die Castings.

Your success is our success. We help companies optimize die casting designs and minimize overall costs.  From design pre-planning, to prototypes, to final finishing, we help our clients achieve high performance.  Our case studies tell the story.

Industry Spotlight: Robotics

Find out how the robotics industry is impacting not only die casting, but a wide array of other industries as well. In this whitepaper, you'll learn about the difference between traditional robots and collaborative robots, the two types of robots used by CWM.

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CWM Case Study: Mg AZ91D Steno Writer Parts

CWM Case Study: Mg AZ91D Steno Writer Parts

This case study describes how Chicago White Metal provided award-winning die castings to a steno writer manufacturer, casting the cosmetic screen backplate and the as-cast internal chassis with magnesium alloy Mg AZ91D.

Click here to view the .PDF: CWM Case Study: Mg AZ91D Steno Writer Parts

Industry Spotlight: Automotive

Industry Spotlight: Automotive

This whitepaper will give you an insight on automotive industry trends, automobiles and die casting, and brief overview CWM case studies that are a few of many live examples of how high pressure die casting serve the automotive industry.

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Industry Spotlight: Medical

Industry Spotlight: Medical

The medical industry is breaking through technological barriers at a rapid rate. With new approaches on the horizon, traditional methods are slowly being phased out and redefined. See how die casting fits into this industry trend in this article, which includes case studies.

Click here to view the .PDF: Industry Spotlight: Medical

10 "Mini" Case Studies for Mini Zinc Parts

10 "Mini" Case Studies for Mini Zinc Parts

Miniature zinc die casting is a precision die casting process that addresses the need for smaller component manufacturing. Learn more about how CWM has helped many different industries with die casting projects in this overview of 10 Case Studies. OEM Tech Brief 47 (April 2015)

Click here to view the .PDF: 10 "Mini" Case Studies for Mini Zinc Parts

Redesign Delivers 40% Unit Cost Saving, 8% Less Weight, Superior Performance

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.

Click here to view the .PDF: Redesign Delivers 40% Unit Cost Saving, 8% Less Weight, Superior Performance

1st-ever Triple Winners in NADCA Die Casting Contest

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)

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Al Archery Bow NADCA Die Casting Award Winner

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)

Click here to view the .PDF: Al Archery Bow NADCA Die Casting Award Winner

Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft

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 lightweight.

Click here to view the .PDF: Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft

GPS Satellite Tracker Unit in Rugged, Lightweight Mg

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.

Click here to view the .PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg

High-Tech Al & Mg for Advanced Video Imaging System

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.

Click here to view the .PDF: High-Tech Al & Mg for Advanced Video Imaging System

Intricate Al Die Cast Propane Vaporizer-Regulator

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.

Click here to view the .PDF: Intricate Al Die Cast Propane Vaporizer-Regulator

Key High-Tech Mg Parts for Optical Survey System

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.

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Medical Imager Mg Multi-function Housing Walls

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 lightweight, multiple functions, and reduced part counts. Each high-tech hot-chamber mag die casting delivers 25 tight-toleranced features as-cast.

Click here to view the .PDF: Medical Imager Mg Multi-function Housing Walls

Mg Die Cast Professional Digital Camera Case

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, lightweight and the quality feel of metal.

Click here to view the .PDF: Mg Die Cast Professional Digital Camera Case

Mg Die Cast Ultrasound Portable Workstation Housing

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.

Click here to view the .PDF: Mg Die Cast Ultrasound Portable Workstation Housing

Mg IMA Process Technology Award for Auto Mirror

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)

Click here to view the .PDF: Mg IMA Process Technology Award for Auto Mirror

Only Mg Met Strength-Weight Specs for Voice/Data Unit

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.

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Portable Die Cast Mg Case with Elastomer Overmolding

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.

Click here to view the .PDF: Portable Die Cast Mg Case with Elastomer Overmolding

Replacement for Machined Brass at a 500% Savings

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.

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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.

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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).

Click here to view the .PDF: Rugged Mg Spotting Scope Die Casting Award