Since 1937, CWM has worked leaner and smarter to produce the most difficult die casting parts in Aluminum, Magnesium & Zinc, making Chicago White Metal your best choice for any die casting project. Regardless of quantity, size, alloy, or finish, we can lower your die casting unit costs on quality die cast parts. Our management systems are IS0 9001 and ISO 14001 registered.
Aluminum Die Castings Process-controlled Aluminum Die Casting Part production, with the latest Magmasoft® simulation plus robotic production automation— delivering die cast aluminum at significantly decreased lead and cycle times with first-piece success.
The first North American custom die caster to use this faster-cycling Mg die casting process, CWM operates one of the largest, most advanced .custom hot-chamber facilities for precision magnesium die casting components.
Zinc Die Castings for high precision and lowest die cast tooling costs. CWM was an early adopter of space-saving thin-wall production of Zinc Die Castings for reduced weight, with no loss in part strength.
Miniature Zinc & ZA-8 multi-slide die casting production: Flash-free, net-shape components ready for final assembly, at low unit costs and minimum tooling investment. CWM specializes in delivering miniature parts with any required post-casting finishing, including precision machining where net shapes are not possible.
Contact Chicago White Metal to discuss die casting options for your next project.
Learn More About Die Casting:
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. View the PDF: The Market for Aluminum Alloys in North America: Trends and Challenges |
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. View the PDF: Book Review: “Poorly Made in China” | |
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. View the PDF: Converting Machined Parts to Die Casting | |
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. View the PDF: Design News Engrg Survey & Key DC2 OEM Resources | |
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. View the PDF: Developing an Optimum Product Design | |
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. View the PDF: EPA-Compliant Chromate for Al, Mg & Zn Parts | |
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. View the PDF: Getting on Course After Onshoring | |
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. View the PDF: How to Select the Best Custom Die Caster | |
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. View the PDF: Special Industrial Robotics Issue | |
A 2-page technical paper. It 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. View the PDF: Still Believe These Five Magnesium Myths? | |
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.” View the PDF: The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S | |
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) View the PDF: The U.S. Aluminum Casting Industry | |
In this issue you will find the following stories: New Employees, Retirements, Condolences, NEW CWM Guides, Design Awards, Perspectives, CWM Investments, Health Fair 2017, Charitable Efforts, CWM and the Morton Arboretum, and more! View the PDF: USA Today: Manufacturing Heading Back to USA? | |
If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a lightweight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands-down choice View the PDF: The Plastic vs Die Casting Process Decision | |
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. View the PDF: Functional-Build Approach to Lower Production 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. View the PDF: How Magmasoft Process Simulation Lowers Costs |
With the demand for Hybrid Electric and Electric Vehicles on the rise, automakers are looking for ways to reduce vehicle weight. They want to improve overall performance, increase fuel or battery efficiency, and extend driving range without sacrificing design or safety. The answer to their problems just might be High-Pressure Die Casting. View the PDF: Electric Vehicles: Component Manufacturing Using the High-Pressure Die Casting Process |
Electric Vehicles: Component Manufacturing Using the High-Pressure Die Casting Process
As a steno writing machine is compact and portable, the use of magnesium provided a lightweight, yet higher quality feel than plastic. The highly cosmetic finishing provides the flawless appearance which the customer was going for. View the PDF: The CWM Difference: Mg AZ91D Steno Writer Parts |
The CWM Difference: Mg AZ91D Steno Writer Parts
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. View the PDF: Developing an Optimum Product Design |
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. View the PDF: Superior EMI Shielding with Die Cast Housings |
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. View the PDF: Tutorial: Electronic Enclosure Design 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. View the PDF: Tutorial: Redesigning a Steel Bracket 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. |
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. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
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. |
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. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
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 a tightened time schedule to tie-in with promotional book and film release dates. NADCA Die Casting Award of Excellence winner. (Includes photos) View the PDF: Al Archery Bow NADCA Die Casting Award Winner |
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. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
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. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
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. View the PDF: Design & Specification Guide for Custom Die Castings |
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. View the PDF: Design of a Bracket for Die Casting Production |
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. View the PDF: Designing for Servicing & Recyclability |
An introductory guide to developing the optimum component configuration for cost-effective die cast processing. It provides an overview of design features that enable the designer to capitalize on the inherent advantages of net-shape die cast production. View the PDF: Designing Optimum Part Shapes |
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. View the PDF: Die Cast Design Myths Can Cripple Optimum Decisions |
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 View the PDF: Die Cast Heat Sink Can Be a Cost-Effective OEM Choice |
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. View the PDF: Die Cast Zn for Key Computer Structural Component |
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. View the PDF: Die Casting Design & Production Preplanning Guide |
The 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. View the PDF: Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft |
Project managers for this satellite positioning system designed an Mg die cast enclosure as advanced as the new technology inside: ultra-rugged; lightweight for field use; waterproof; dustproof, with fail-safe EMI shielding. View the PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg |
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. View the PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg |
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. View the PDF: Intricate Al Die Cast Propane Vaporizer-Regulator |
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. View the PDF: Key High-Tech Mg Parts for Optical Survey System |
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. View the PDF: Leveraging DFM Prior to Design Commitment |
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. Watch: Machining to Die Casting: A Guide to Conversion Webinar |
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. View the PDF: Magnesium EMI Shielding Characteristics |
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. View the PDF: Medical Imager Mg Multi-function Housing Walls |
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. View the PDF: Mg Die Cast Professional Digital Camera Case |
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. View the PDF: Mg Die Cast Ultrasound Portable Workstation Housing |
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) View the PDF: Mg IMA Process Technology Award for Auto Mirror |
This in-depth White Paper from the North American Die Casting Assn. details of 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. View the PDF: NADCA Collaborative Engineering White Paper |
Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. View the PDF: NADCA Design Manual: Intro & Content |
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) View the PDF: NADCA-ADCI Standards Cross-Reference Chart |
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. View the PDF: NADCA: Comparison of Mag Die Casting & Plastic Parts |
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. View the PDF: NADCA: Coordinate vs Geometric Dimensioning Intro |
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) View the PDF: NADCA: Die Cast Production & Finishing Checklists |
A 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. View the PDF: NADCA: For Efficient Manufacturing, Look to Die Casting |
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. View the PDF: NADCA: Pointers for Designing Die Castings |
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. View the PDF: NADCA: Product Standards Manual Overview |
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. View the PDF: NADCA: Tooling Checklists for Die Casting Dies |
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. View the PDF: Only Mg Met Strength-Weight Specs for Voice/Data Unit |
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. View the PDF: Overview of CWM Die Casting & Production Capabilities |
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. View the PDF: Portable Die Cast Mg Case with Elastomer Overmolding |
Overmolding of a die cast enclosure allows product advantages beyond the soft-touch characteristics of elastomers. Tech Brief outlines design considerations that should be addressed by the design engineer planning a marriage of die casting and elastomer overmolding. View the PDF: Preliminary Guide to Overmolding of Die Cast Parts |
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 |
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. |
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 |
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. The new model offers an Al die cast metal housing to meet extreme, rugged field conditions, difficult for plastic housings to survive. View the PDF: Rugged Al Die Cast Laser Housing Outperforms Plastic |
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). View the PDF: Rugged Mg Spotting Scope Die Casting Award |
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) View the PDF: NADCA-ADCI Standards Cross-Reference Chart |
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. View the PDF: Die Casting Design & Production Preplanning Guide |
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. View the PDF: Only Mg Met Strength-Weight Specs for Voice/Data Unit |
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 |
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. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
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. View the PDF: Portable Die Cast Mg Case with Elastomer Overmolding |
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. View the PDF: Prototyping for Die Casting in All Alloys |
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. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
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 |
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. View the PDF: Quick Guide to Surface Finishing for Al, Mg & Zn Parts |
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. View the PDF: Design & Specification Guide for Custom Die Castings |
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. The new model offers an Al die cast metal housing to meet extreme, rugged field conditions, difficult for plastic housings to survive. View the PDF: Rugged Al Die Cast Laser Housing Outperforms Plastic |
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. View the PDF: Superior EMI Shielding with Die Cast Housings |
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) View the PDF: 1st-ever Triple Winners in NADCA Die Casting Contest |
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). View the PDF: Rugged Mg Spotting Scope Die Casting Award |
Brief overview of surface treatment systems for die cast part protection, decoration, and improving component performance, for all alloys: Al, Mg, Zn, and ZA. View the PDF: Surface Finishing for Die Casting Bulletin |
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 a tightened time schedule to tie-in with promotional book and film release dates. NADCA Die Casting Award of Excellence winner. (Includes photos) View the PDF: Al Archery Bow NADCA Die Casting Award Winner |
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. |
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. View the PDF: Die Cast Design Myths Can Cripple Optimum Decisions |
If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a lightweight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands-down choice View the PDF: The Plastic vs Die Casting Process Decision |
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. View the PDF: Die Cast Zn for Key Computer Structural Component |
A 2-page technical paper. It 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. View the PDF: Still Believe These Five Magnesium Myths? |
Introductory overview and guide to optimum materials and alternate process selection. It contains a physical and mechanical materials properties comparison chart for the most widely used Al, Mg & Zn die casting alloys. View the PDF: Evaluating Materials & Processes |
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. View the PDF: Tutorial: Redesigning a Steel Bracket for Die Casting |
The 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. View the PDF: Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft |
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. View the PDF: Material / Physical Properties Comparison |
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. View the PDF: Magnesium EMI Shielding Characteristics |
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. View the PDF: Leveraging DFM Prior to Design Commitment |
Project managers for this satellite positioning system designed an Mg die cast enclosure as advanced as the new technology inside: ultra-rugged; lightweight for field use; waterproof; dustproof, with fail-safe EMI shielding. View the PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg |
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. View the PDF: Developing an Optimum Product Design |
Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. View the PDF: NADCA Design Manual: Intro & Content |
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. |
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. View the PDF: High-Tech Al & Mg for Advanced Video Imaging System |
Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Aluminum Alloy Data |
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. |
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. View the PDF: Intricate Al Die Cast Propane Vaporizer-Regulator |
Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Magnesium Alloy Data |
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. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
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. View the PDF: Key High-Tech Mg Parts for Optical Survey System |
Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Zinc & ZA Alloy Data |
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. |
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. View the PDF: Medical Imager Mg Multi-function Housing Walls |
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. View the PDF: NADCA: Comparison of Mag Die Casting & Plastic 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. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
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. View the PDF: Mg Die Cast Professional Digital Camera Case |
A 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. View the PDF: NADCA: For Efficient Manufacturing, Look to Die Casting |
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 View the PDF: Die Cast Heat Sink Can Be a Cost-Effective OEM Choice |
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. View the PDF: Mg Die Cast Ultrasound Portable Workstation Housing |
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. View the PDF: NADCA: Product Standards Manual Overview |
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. View the PDF: Designing for Servicing & Recyclability |
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) View the PDF: Mg IMA Process Technology Award for Auto Mirror |
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. View the PDF: Converting Machined Parts to Die Casting |
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. View the PDF: Design News Engrg Survey & Key DC2 OEM Resources |
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) View the PDF: The Market for Aluminum Alloys in North America: Trends and Challenges |
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. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
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) View the PDF: 1st-ever Triple Winners in NADCA Die Casting Contest |
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 a tightened time schedule to tie-in with promotional book and film release dates. NADCA Die Casting Award of Excellence winner. (Includes photos) View the PDF: Al Archery Bow NADCA Die Casting Award Winner |
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. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
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. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
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. View the PDF: Design & Specification Guide for Custom Die Castings |
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. View the PDF: Die Casting Design & Production Preplanning Guide |
The 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. View the PDF: Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft |
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. View the PDF: High-Tech Al & Mg for Advanced Video Imaging System |
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. View the PDF: Intricate Al Die Cast Propane Vaporizer-Regulator |
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. View the PDF: Material / Physical Properties Comparison |
Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Aluminum Alloy Data |
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. |
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. View the PDF: Prototyping for Die Casting in All Alloys |
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. View the PDF: Quick Guide to Surface Finishing for Al, Mg & Zn Parts |
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. The new model offers an Al die cast metal housing to meet extreme, rugged field conditions, difficult for plastic housings to survive. View the PDF: Rugged Al Die Cast Laser Housing Outperforms Plastic |
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. |
Brief overview of surface treatment systems for die cast part protection, decoration, and improving component performance, for all alloys: Al, Mg, Zn, and ZA. View the PDF: Surface Finishing for Die Casting Bulletin |
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. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
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) View the PDF: The U.S. Aluminum Casting Industry |
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. View the PDF: Redesign Delivers 40% Unit Cost Saving, 8% Less Weight, Superior Performance |
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. View the PDF: Die Casting’s Answer to Plastic: Magnesium |
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. |
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. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
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) View the PDF: 1st-ever Triple Winners in NADCA Die Casting Contest |
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. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
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. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
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. View the PDF: Design & Specification Guide for Custom Die Castings |
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. View the PDF: Die Casting Design & Production Preplanning Guide |
The 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. View the PDF: Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft |
Project managers for this satellite positioning system designed an Mg die cast enclosure as advanced as the new technology inside: ultra-rugged; lightweight for field use; waterproof; dustproof, with fail-safe EMI shielding. View the PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg |
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. View the PDF: High-Tech Al & Mg for Advanced Video Imaging 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. View the PDF: Key High-Tech Mg Parts for Optical Survey System |
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. View the PDF: Magnesium EMI Shielding Characteristics |
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. View the PDF: Material / Physical Properties Comparison |
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. View the PDF: Medical Imager Mg Multi-function Housing Walls |
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. View the PDF: Mg Die Cast Professional Digital Camera Case |
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. View the PDF: Mg Die Cast Ultrasound Portable Workstation Housing |
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) View the PDF: Mg IMA Process Technology Award for Auto Mirror |
Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Magnesium Alloy Data |
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. View the PDF: NADCA: Comparison of Mag Die Casting & Plastic Parts |
Ruggedness, impact strength, and lightweight 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. View the PDF: Only Mg Met Strength-Weight Specs for Voice/Data Unit |
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. View the PDF: Portable Die Cast Mg Case with Elastomer Overmolding |
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. |
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. View the PDF: Prototyping for Die Casting in All Alloys |
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. View the PDF: Quick Guide to Surface Finishing for Al, Mg & Zn Parts |
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). View the PDF: Rugged Mg Spotting Scope Die Casting Award |
A 2-page technical paper. It 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. View the PDF: Still Believe These Five Magnesium Myths? |
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. |
Brief overview of surface treatment systems for die cast part protection, decoration, and improving component performance, for all alloys: Al, Mg, Zn, and ZA. View the PDF: Surface Finishing for Die Casting Bulletin |
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. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a lightweight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands-down choice View the PDF: The Plastic vs Die Casting Process Decision |
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. For those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
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. |
6-page guide outlines ten 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. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
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. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
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. View the PDF: CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data |
Updated and expanded 16-page reference to the initial design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among essential 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. View the PDF: Design & Specification Guide for Custom Die Castings |
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. View the PDF: Die Cast Zn for Key Computer Structural Component |
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 |
Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. View the PDF: NADCA Design Manual: Intro & Content |
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. View the PDF: Material / Physical Properties Comparison |
Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Zinc & ZA Alloy Data |
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 |
Guide to developing optimum prototyping strategies for developing and testing component designs before final die casting die construction. This guide discusses prototyping alloys and processes, including new rapid prototyping technologies. View the PDF: Prototyping for Die Casting in All Alloys |
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. View the PDF: Quick Guide to Surface Finishing for Al, Mg & Zn Parts |
Brief overview of surface treatment systems for die cast part protection, decoration, and improving component performance, for all alloys: Al, Mg, Zn, and ZA. View the PDF: Surface Finishing for Die Casting Bulletin |
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. |
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. |
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 |
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 |
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. |
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. View the PDF: CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data |
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 |
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. View the PDF: CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data |
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. View the PDF: Design of a Bracket for Die Casting Production | |
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. View the PDF: Material / Physical Properties Comparison | |
This is a comprehensive resource on accepted contractual purchasing practices for purchasing die casting and related services based on established industry trade customs and prepared by the North American Die Casting Assn. It 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. View the PDF: NADCA Commercial Practices for Die Casting Buyers | |
Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Aluminum Alloy Data | |
Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Magnesium Alloy Data | |
Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Zinc & ZA Alloy Data | |
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. View the PDF: NADCA: Coordinate vs. Geometric Dimensioning Intro | |
Key factors in specifying the production and surface finishing of die cast parts, based on NADCA Product Standards Manual guidelines. Helps assure more transparent communication between OEM purchaser and die caster. (2015) View the PDF: NADCA: Die Cast Production & Finishing Checklists | |
Illustrated condensed overview of the essential contents of the die casting industry’s authoritative “Product Specification Standards for Die Castings” reference manual, as initially established in 1997. View the PDF: NADCA: Product Standards Manual Overview | |
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. View the PDF: NADCA: Tooling Checklists for Die Casting Dies | |
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) View the PDF: NADCA-ADCI Standards Cross-Reference Chart | |
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 recorded documents. View the PDF: Die Casting Design & Production Preplanning Guide | |
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. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure | |
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. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
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 revealed before tooling construction. View the PDF: How Magmasoft Process Simulation Lowers Costs |
In-depth White Paper from the North American Die Casting Assn. details of 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. View the PDF: NADCA Collaborative Engineering White Paper |
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. It 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. View the PDF: NADCA Commercial Practices for Die Casting Buyers |
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. View the PDF: NADCA: Tooling Checklists for Die Casting Dies |
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. |
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. |
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. For those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
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. |
6-page guide outlines ten 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. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
Presents data on heat sink materials comparisons and the strengths and weaknesses of heat sinks produced as stampings, extrusions, and die castings. Of particular interest to designers less familiar with integral incorporation of heat sinks into a housing design or the potential of custom die cast sink designs. View the PDF: Die Cast Heat Sink Can Be a Cost-Effective OEM Choice |
This in-depth White Paper from the North American Die Casting Assn. details of 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. View the PDF: NADCA Collaborative Engineering White Paper |
Updated and expanded 16-page reference to the superior design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among essential 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. View the PDF: Design & Specification Guide for Custom Die Castings |
Learn more about the Die Cast Die with this document, taken from the NADCA Standards Book (2021). View the PDF: NADCA: Tooling for Die Casting |
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. |
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. For those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
6-page guide outlines ten 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. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
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. View the PDF: Overview of CWM Die Casting & Production Capabilities |
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. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
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. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
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. View the PDF: CWM CNC Machining Capabilities Brochure |
This in-depth White Paper from the North American Die Casting Assn. details of 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. View the PDF: NADCA Collaborative Engineering White Paper |
Updated and expanded 16-page reference to the superior design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among essential 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. View the PDF: Design & Specification Guide for Custom Die Castings |
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. View the PDF: Key High-Tech Mg Parts for Optical Survey System |
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 |
Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Aluminum Alloy Data |
Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Magnesium Alloy Data |
Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Zinc & ZA Alloy Data |
This presentation will aid OEM product designers, engineers, and specifiers with valuable, practical guidelines for assuring sound design-for-manufacturing decisions before freezing their designs destined for die casting production. View the PDF: Leveraging DFM Before Design Commitment |
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. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
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. |
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. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
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. View the PDF: Overview of CWM Die Casting & Production Capabilities |
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. View the PDF: EPA-Compliant Chromate for Al, Mg & Zn Parts |
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. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
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. It 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. View the PDF: NADCA Commercial Practices for Die Casting Buyers |
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. View the PDF: Design & Specification Guide for Custom Die Castings |
Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Aluminum Alloy Data |
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) View the PDF: Al Archery Bow NADCA Die Casting Award Winner |
Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Magnesium Alloy Data |
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. View the PDF: Die Cast Zn for Key Computer Structural Component |
Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Zinc & ZA Alloy Data |
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) View the PDF: NADCA: Die Cast Production & Finishing Checklists |
Overmolding of a die cast enclosure allows product advantages beyond the soft-touch characteristics of elastomers. Tech Brief outlines design considerations that should be addressed by the design engineer planning a marriage of die casting and elastomer overmolding. View the PDF: Preliminary Guide to Overmolding of Die Cast 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. View the PDF: Quick Guide to Surface Finishing for Al, Mg & Zn Parts |
Brief overview of surface treatment systems for die cast part protection, decoration, and improving component performance, for all alloys: Al, Mg, Zn, and ZA. View the PDF: Surface Finishing for Die Casting Bulletin |
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. View the PDF: Tutorial: Electronic Enclosure Design for Die Casting |
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. View the PDF: Leveraging DFM Prior to Design Commitment |
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. |
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. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
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) View the PDF: Mg IMA Process Technology Award for Auto Mirror |
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 View the PDF: Die Cast Heat Sink Can Be a Cost-Effective OEM Choice |
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. View the PDF: Only Mg Met Strength-Weight Specs for Voice/Data Unit |
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. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
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. View the PDF: Portable Die Cast Mg Case with Elastomer Overmolding |
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. View the PDF: CWM Miniature Die Casting Capabilities Profile, Specifications, Alloy Data |
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 |
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. View the PDF: Converting Machined Parts to Die Casting |
This in-depth White Paper from the North American Die Casting Assn. details of 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. View the PDF: NADCA Collaborative Engineering White Paper |
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. |
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. View the PDF: Functional-Build Approach to Lower Production Costs |
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. View the PDF: Design & Specification Guide for Custom Die Castings |
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. View the PDF: Hidden Costs of Sourcing Die Castings Offshore |
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) View the PDF: 1st-ever Triple Winners in NADCA Die Casting Contest |
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. View the PDF: How Magmasoft Process Simulation Lowers Costs |
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. View the PDF: Die Cast Zn for Key Computer Structural Component |
In-depth White Paper from the North American Die Casting Assn. details of 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. View the PDF: NADCA Collaborative Engineering White Paper |
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. View the PDF: Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft |
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. View the PDF: NADCA: Pointers for Designing Die Castings |
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. View the PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg |
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.” View the PDF: The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S |
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. View the PDF: High-Tech Al & Mg for Advanced Video Imaging System |
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, View the PDF: USA Today: Manufacturing Heading Back to USA? |
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. View the PDF: Intricate Al Die Cast Propane Vaporizer-Regulator |
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. |
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. View the PDF: Key High-Tech Mg Parts for Optical Survey System |
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. |
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. View the PDF: Medical Imager Mg Multi-function Housing Walls |
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. |
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. View the PDF: Mg Die Cast Professional Digital Camera Case |
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. |
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. View the PDF: Mg Die Cast Ultrasound Portable Workstation Housing |
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. View the PDF: Redesign Delivers 40% Unit Cost Saving, 8% Less Weight, Superior Performance |
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. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
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. View the PDF: Converting Machined Parts to Die Casting |
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. View the PDF: Design of a Bracket for Die Casting Production |
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 View the PDF: Die Cast Heat Sink Can Be a Cost-Effective OEM Choice |
Introductory overview and guide to optimum materials and alternate process selection. It contains a physical and mechanical materials properties comparison chart for the most widely used Al, Mg & Zn die casting alloys. View the PDF: Evaluating Materials & Processes |
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. View the PDF: Leveraging DFM Prior to Design Commitment |
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. |
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. |
Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. View the PDF: NADCA Design Manual: Intro & Content |
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. View the PDF: NADCA: Comparison of Mag Die Casting & Plastic Parts |
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. View the PDF: Portable Die Cast Mg Case with Elastomer Overmolding |
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 |
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. |
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. The new model offers an Al die cast metal housing to meet extreme, rugged field conditions, difficult for plastic housings to survive. View the PDF: Rugged Al Die Cast Laser Housing Outperforms Plastic |
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. |
If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a lightweight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands-down choice View the PDF: The Plastic vs Die Casting Process Decision |
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. View the PDF: Tutorial: Electronic Enclosure Design 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. View the PDF: Tutorial: Redesigning a Steel Bracket for Die Casting |
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. View the PDF: Prototyping for Die Casting in All Alloys |
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. View the PDF: Leveraging DFM Prior to Design Commitment |
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. |
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. View the PDF: Overview of CWM Die Casting & Production Capabilities |
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. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
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. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
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. View the PDF: Design & Specification Guide for Custom Die Castings |
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. View the PDF: EPA-Compliant Chromate for Al, Mg & Zn Parts |
A 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. View the PDF: NADCA: For Efficient Manufacturing, Look to Die Casting |
If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a lightweight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands-down choice View the PDF: The Plastic vs Die Casting Process Decision |
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. View the PDF: Designing for Servicing & Recyclability |
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) View the PDF: 1st-ever Triple Winners in NADCA Die Casting Contest |
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. View the PDF: Mg Die Cast Professional Digital Camera Case |
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. View the PDF: How Magmasoft Process Simulation Lowers Costs |
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. View the PDF: Magnesium EMI Shielding Characteristics |
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. View the PDF: NADCA: Comparison of Mag Die Casting & Plastic Parts |
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. |
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. View the PDF: Die Casting Design & Production Preplanning Guide |
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. View the PDF: Overview of CWM Die Casting & Production Capabilities |
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. View the PDF: CWM Comprehensive Die Casting Capabilities Brochure |
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. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
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. It 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. View the PDF: NADCA Commercial Practices for Die Casting Buyers |
Updated and expanded 16-page reference to the superior design & specification steps that drive the cost and performance of components die cast in Al, Mg, and Zn alloys. Among essential 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. View the PDF: Design & Specification Guide for Custom Die Castings |
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. View the PDF: NADCA: Comparison of Mag Die Casting & Plastic Parts |
Key factors in specifying the production and surface finishing of die cast parts, based on NADCA Product Standards Manual guidelines. Helps assure more transparent communication between OEM purchaser and die caster. (2015) View the PDF: NADCA: Die Cast Production & Finishing Checklists |
A 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, also, 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. View the PDF: NADCA: For Efficient Manufacturing, Look to Die Casting |
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.” View the PDF: The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S |
August 2010 article reports on plans for significant 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, View the PDF: USA Today: Manufacturing Heading Back to USA? |
This presentation will aid OEM product designers, engineers, and specifiers with valuable, practical guidelines for assuring sound design-for-manufacturing decisions before freezing their designs destined for die casting production. View the PDF: Leveraging DFM Prior to Design Commitment |
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. |
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 original businessman-author documents. View the PDF: Book Review: “Poorly Made in China” |
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. |
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 essential 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. View the PDF: Design News Engrg Survey & Key DC2 OEM Resources |
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. |
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. View the PDF: Die Cast Design Myths Can Cripple Optimum Decisions |
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. For those new to the process, it provides a valuable framework or further pursuit. View the PDF: The Die Casting Process: An OEM Designer’s Overview |
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. View the PDF: Die Casting Spec & Sourcing Aids for OEM Buyers |
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. |
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. View the PDF: Hidden Costs of Sourcing Die Castings Offshore |
6-page guide outlines ten 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. View the PDF: 10 Ways to Reduce the Costs of Die Cast Parts |
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. View the PDF: How to Select the Best Custom Die Caster |
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. The announcement contains direct Web links to aid access or requests for all recorded documents. View the PDF: Die Casting Design & Production Preplanning Guide |
Outlines EMI/RFI shielding requirements for electronic assemblies. Presents relationships between standard measures of shielding, advantages of die castings in general, and mag die castings in particular, for electronic enclosure shielding. Norsk Hydro Magnesium prepares them. View the PDF: Magnesium EMI Shielding Characteristics |
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. View the PDF: CWM Al, Mg & Zn Die Cast Production Specs |
In-depth White Paper from the North American Die Casting Assn. details of 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. View the PDF: NADCA Collaborative Engineering White Paper |
Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Aluminum Alloy Data |
Mg alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Magnesium Alloy Data |
Updated Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics. View the PDF: NADCA Standards: Zinc & ZA Alloy Data |
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. View the PDF: Superior EMI Shielding with Die Cast Housings |
If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a lightweight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands-down choice View the PDF: The Plastic vs Die Casting Process Decision |
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. View the PDF: Tutorial: Electronic Enclosure Design for Die Casting |
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. View the PDF: Die Cast Zn for Key Computer Structural Component |
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. View the PDF: GPS Satellite Tracker Unit in Rugged, Lightweight Mg |
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). View the PDF: Rugged Mg Spotting Scope Die Casting Award |
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 original businessman-author documents. View the PDF: Book Review: “Poorly Made in China” |
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. View the PDF: Hidden Costs of Sourcing Die Castings Offshore |
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.” View the PDF: The Insourcing Boom: Updated, In-depth look at the Comeback of Manufacturing to the U.S |
August 2010 article reports on plans for significant 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, View the PDF: USA Today: Manufacturing Heading Back to USA? |
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. View the PDF: Rising Wages, Acknowledgment of Hidden Costs Bring Manufacturing Back to U.S. Shores |
A 2-page NADCA report on US jobs and outsourcing. Reviews US job loss and potential return. View the PDF: U.S. Manufacturing… Pain & Promise |
