Miniature zinc die casting offers the highest precision at the lowest tooling cost.
Miniature zinc die casting is the process of choice for small complex components. Utilizing machines and dies specifically designed for the production of small parts, the miniature zinc process can produce net shape, flash-free parts. While this process is similar to the hot-chamber die casting CWM employees for larger parts, it is capable of holding tolerances as tight as +/- .001″, and walls as thin as 0.020″, in parts weighing up to .75 lbs.
Major advantages of the miniature die casting process include:
- Ability to die cast complex net shape, flash-free parts with specified features and tolerances as-cast
- No post-casting machining, with gate removal eliminated by automated degating or part-on-part deburring.
Because no trim tool is required and tools are significantly smaller, miniature zinc die cast tooling is often far less costly than conventional tooling.
Although part intricacy drives tooling cost, a simple 2 x 2 inch miniature die cast tool can cost as little as $8,500.
Long tool life is another advantage of the process, with up to 1MM cycles possible.
Finally, because of the fast cycle times, the cost of parts are generally a fraction of the cost of conventional die casting, typically costing pennies compared to dollars, making miniature die casting an excellent choice for small parts.
CWM offers zinc alloys #3, #5, #7, and ZA8, each with their own advantages. Miniature zinc die casting can economically replace other manufacturing processes such as plastic, screw machine, cold heading, and stamping, while offering greater dimensional control and lower costs.
Miniature zinc die cast components are often used “as-cast” with no further surface treatment. If required, however, CWM offers a broad range of cosmetic and functional finish options. These include corrosion protection coatings, plating, paint, or electro deposited coatings. And, when extremely tight tolerances are specified, CWM provides a complete range of CNC and conventional machining capabilities.
Learn More About Miniature Zinc Die Casting:
Converting Machined Parts to Die Casting
When production runs for a machined 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.
View the PDF: Converting Machined Parts to Die Casting
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.
View the PDF: Primer on Miniature Zinc & ZA-8 Die Casting
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.
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.
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.
View the PDF: Replacement for Machined Brass at a 500% Savings