<p>We offer die casting solutions that guarantee consistent quality and rapid deployment for business applications and the demanding needs of modern data centers.</p>

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Enterprise Technology

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Dynacast delivers precision die castings with unmatched dimensional consistency, ensuring optimal performance and compatibility in complex enterprise systems as well as high-demand data centers.

Dimensional Accuracy

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The die casting process allows for efficient production, accelerating time-to-market.

Rapid Production

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Dynacast supports a wide range of metal materials, including alloys optimized for specific technological requirements such as conductivity, heat resistance, or lightweight properties.

Material Variety

In the fast-paced enterprise technology sector, rapid time-to-market is crucial, and Dynacast maintains consistent quality across high volumes of components.

High Production Rates 

Enterprise Technology Leaders Choose Dynacast To Help Achieve Key Goals

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Enterprise Technology Applications

<p>SICK faced the challenge of creating a miniature, intricate sensor housing for their picoScan100 2D LiDAR sensor, requiring precision, durability, and near-perfect internal tolerances while navigating manufacturing complexities like limited draft angles and shot accuracy.</p>

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The Problem

<p>Dynacast provided collaborative design support, simulation-driven precision, and micro-casting to optimize the manufacturing of SICK's complex sensor housing, leveraging multi-slide die casting and offering end-to-end solutions from design to production.</p>

Precision in Partnership

<p>The collaboration resulted in seamless integration, with the sensor housing meeting all performance requirements and being delivered on time and within specifications. SICK expressed full satisfaction with Dynacast's execution and the flawless performance of the final product.</p><p></p><p><em>“Smooth implementation of the entire project without additional corrections” – SICK</em></p>

Flawless Execution

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<h2><strong>The Challenge: Ensuring Strict Quality in Safety-Critical Die Cast Tool Transfers</strong></h2><p>A prominent manufacturer of air brake systems for heavy-duty trucks needed a reliable die casting partner to ensure the continuity and quality of their safety-critical components. With their production reliant on <a href="/metals/zinc" target="_self">zinc die cast parts</a>, they were faced with several critical tools needing to be transferred with zero disruption to their manufacturing schedule.</p><p>The company turned to Dynacast’s Peterborough facility, having previously experienced the team's technical reliability and industry expertise.</p><h2><strong>The Solution: Expertise, Communication, and Precision Engineering</strong></h2><p>Dynacast’s longstanding partnership with the customer laid the groundwork for a <a href="/additional-capabilities/tooling" target="_self">die cast tooling transfer</a> that was both technically sound and operationally seamless. The project’s success hinged on three pillars:</p><ol><li><strong>Open Communication and Dedicated Support</strong><br />Clear, proactive dialogue ensured alignment between both teams. Dynacast provided continuous technical support throughout the transition, enabling fast decision-making and issue resolution.</li><li><strong>Flawless Tooling Integration</strong><br />The transfer process was meticulously managed, with the tooling relocated directly to the Peterborough site for immediate integration into production.</li><li><strong>Relentless Focus on Quality</strong><br />With safety-critical parts in scope, Dynacast maintained stringent quality standards every step of the way—protecting both performance and customer trust.</li></ol><h2><strong>Engineering Highlights: Solving for the Unknown</strong></h2><p><strong>The absence of existing CAD files or tool documentation added complexity to the situation.</strong></p><p>The <a href="/additional-capabilities/engineering" target="_self">engineering team</a> began with a <strong>comprehensive tool assessment</strong>, manually evaluating each tool to determine its condition, shot life, and overall suitability for continued use. With no existing CAD data or tool files, this hands-on inspection was critical to ensuring a reliable production setup.</p><p>Following the assessment, the team executed a <strong>direct facility transfer</strong>, transporting the tools straight to Dynacast’s Peterborough facility.</p><h2><strong>The Outcome: A Smooth Die Cast Tooling Transfer</strong></h2><p>The tooling transfer was completed successfully and fully integrated into production—without causing any disruption to the customer’s schedule. From the outset, Dynacast maintained the high-quality standards required for safety-critical components, ensuring reliable performance and consistency from day one.</p>

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Discover how Dynacast ensured seamless production of safety-critical air brake components through transferring die cast tooling.

Tooling Transfer for Air Brake Parts | Dynacast Case Study

In this case study, you’ll learn how Dynacast helped a leading air brake system manufacturer seamlessly transfer critical die cast tooling—without disrupting production or compromising safety. You’ll see how clear communication, hands-on engineering, and a relentless focus on quality made it possible to maintain high performance and trust in a safety-critical environment.

How Dynacast Seamlessly Transferred Safety-Critical Tooling

<p>Aluminum is one of the most commonly used materials in die casting. It’s lightweight, strong, rigid, and can withstand high temperatures, which makes it common across many industries. Some other qualities of aluminum include:</p><ul><li>Good stiffness and strength-to-weight ratio</li><li>Corrosion resistance</li><li>Heat dissipating</li><li>Fully recyclable</li><li>Ideal for harsh environments</li><li>Excellent EMI shielding properties</li><li>Excellent thermal conductivity</li><li>Good finishing characteristics</li><li>Good machining characteristics</li></ul><h2><strong>Aluminum Alloys</strong></h2><p>At Dynacast, the <a href="/metals/aluminum" target="_self">aluminum alloys</a> that are most commonly used in North America are A380, 383 and 413 with their equivalent Asian and European alloys being used in other regions. However, a number of other alloys are available depending on customer requirements and product design needs. Unlike primary aluminum alloys that have to be mined and extracted from ore, these secondary alloys are derived from primary aluminum scrap, which means they are more environmentally friendly. Dynacast has aluminum plants all over the world, which means your aluminum parts can be manufactured in a location that’s best for you. </p><p>Below are two industry examples of how aluminum can be used:</p><h3><strong>Automotive</strong></h3><p>Unlike conventional <a href="/die-casting-technologies/hot-chamber-die-casting" target="_self">hot chamber die casting</a>, which utilizes a two-part tool, <a href="/die-casting-technologies/multi-slide" target="_self">multi-slide die casting</a> employs four perpendicular slides in the tool, allowing for the creation of intricate and precise castings. This technology provides design freedom, enabling the production of complex geometries with unmatched accuracy.</p><h3><strong>Handheld Devices</strong></h3><p>Aluminum die cast shields and housings give EMI shielding, rigidity, and durability with minimal additional weight for handheld devices. This becomes an important quality when emission and interference suppression requirements are high.</p><p>&nbsp;</p>

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Explore the benefits of aluminum die casting—lightweight, strong, and corrosion-resistant. Discover Dynacast's expertise in aluminum components.

Aluminum Die Casting Spotlight | Dynacast Article

Aluminum die has benefits and applications in various industries. Key applications include automotive and handheld devices.

Aluminum Die Casting Spotlight

<h1>Multi-Award Winning Die Casting Facility</h1><p>Dynacast Elgin creates over a million precision zinc and aluminum die cast components each day from their 112,000 square foot facility. While that number alone is impressive, the real story lies in the people who and the number of award-winning components this facility has produced. We believe that the foundation of any successful project lies within the component design. For Dynacast Elgin that starts with their engineering team, winners of two International Die Casting Design Awards this past year.</p><p>While the award-winning components were created for automotive applications, each had very different functions and both were previously produced using a different manufacturing process. The over 6oz category winner was previously a machined aluminum extrusion assembly. The <a href="/additional-capabilities/engineering" target="_self">Dynacast engineering team</a> designed the part into a single component, utilizing Zamak 3 that incorporated necessary mounting features. The under 6oz category winner was previously a stamped component. Utilizing the facilities’ state-of-the-art software, the Elgin engineering team modified this part and designed it for the die casting process resulting in a higher strength component than the previously stamped version. Both redesigns reduced the overall part cost for the customer.</p><p>The team takes pride in helping customers determine the best materials and processes to deliver the best results for their business. They are driven to produce any component that customers bring to the table. With over 12 NADCA die casting awards, the Elgin engineering team has proven successfully their design for manufacturability techniques can create components other die casters simply cannot.</p><h2>In-House Capabilities</h2><p>Utilizing design, prototyping and modeling services, Dynacast Elgin provides manufacturing solutions to customers all over North America. Not only does Elgin <a href="/additional-capabilities/tooling" target="_self">build their tools in-house</a>, they also run 9 aluminum die casting machines and 76 multi-slide zinc die casting machines—ranging from 4-600 ton locking force and part size varying from 1g to 7lbs. In addition to the wide array of die casting machines, Elgin has over 25 CNC machines—plus dedicated tapping, reaming, and drilling machines—far exceeding the capabilities of other die casters.</p><p>Additionally, Elgin’s specialty <a href="/additional-capabilities/secondary-operations" target="_self">secondary manufacturing department</a> and their robust network of certified suppliers supports many best-in-class manufacturers from a variety of industries including medical equipment &amp; devices, telecommunications, consumer electronics, and automotive—both electronics and safety-critical components.</p><h2>Operational Excellence</h2><p>Elgin was one of the first Dynacast facilities to implement FOS (Form Technologies Operating System.) The FOS platform incorporates a coordinated set of procedures for identifying problems, implementing changes, and developing easily repeatable systems that can be adopted into everyday practices. By utilizing 5S and other lean manufacturing techniques, Elgin has drastically improved the overall performance of the plant resulting in a positive impact on their customers. This new philosophy is not just a strategy implemented by management but a culture that has improved their way of thinking allowing them to maximize productivity and reduce waste.</p><p><em>Dynacast Elgin is the recipient of the NADCA safety award for achieving an outstanding record that exceeds national manufacturing averages. </em></p><h2>Midwest NAFTA Die Casting Company</h2><p>Dynacast Elgin is a NAFTA certified die caster that works with organizations all over the world, helping bring their ideas to life with the highest quality die cast components around the globe. Utilizing only certified alloys, Elgin delivers the results their customers need with the cost-effectiveness their business demands. Learn how to simplify your die casting process and reduce costs, <a href="/locations/dynacast-elgin" target="_self">contact Dynacast Elgin</a> today to speak with someone from their local team or request a plant tour.</p>

Explore the capabilities of Dynacast’s Elgin facility, specializing in high-precision die casting and advanced manufacturing solutions.

Dynacast Elgin Facility Spotlight | Advanced Die Casting

Dynacast Elgin, a multi-award-winning die casting facility, produces over a million precision zinc and aluminum components daily, driven by a skilled team known for their innovative designs, extensive in-house capabilities, and commitment to operational excellence. 

Facility Spotlight: Dynacast Elgin

Enhanced Performance for LiDAR Sensor Housings

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<p>As industries continue to push the boundaries of lightweight metal components without compromising safety, a breakthrough material is now playing a pivotal role in Dynacast Austria’s latest manufacturing advancement: <strong>MgCarbonit91</strong>. This innovative magnesium alloy combines exceptional castability with a unique fire-retardant capability—contributing to safer, lighter parts produced through <a href="/additional-capabilities/thixomolding" target="_self">thixomolding</a>.</p><h2><strong>MgCarbonit91: A High-Strength, Fire-Retardant Magnesium Alloy</strong></h2><p>Traditionally, the challenge with <a href="/metals/magnesium" target="_self">magnesium alloys</a> has been striking the right balance between flame resistance and mechanical strength. While earlier compositions have improved ignition temperatures to meet flame-resistance standards, they often did so at the expense of structural performance—especially when compared to the widely used MgAZ91 alloy.</p><p>MgCarbonit91 solves this challenge. <strong>By adding carbon nanoparticles, it maintains the strong mechanical properties of traditional magnesium alloys. The result is a material that is </strong><strong>flame-resistant</strong><strong>.</strong></p><h2><strong>Thixomolding's Impact on </strong><strong>Aerospace, Electronics and More</strong></h2><p>Dynacast Austria is leveraging the benefits of MgCarbonit91 in its new semi-solid metal processing technique, Dynathixo, which is ideal for producing high-precision magnesium parts. MgCarbonit91’s thixomoldability ensures smooth flow, minimal porosity, and consistent surface finish—even in intricate mold designs.</p><p>This development positions Austria as a central hub in Dynacast’s global network for magnesium applications, particularly in high-stakes sectors like aerospace, electronics, and energy storage.</p><h2><strong>MgCarbonit91 vs. Aluminum</strong></h2><p>Weighing in at just two-thirds the density of aluminum, MgCarbonit91 enables substantial weight reductions without compromising strength or safety. Its properties make it ideal for use in aircraft interiors and other applications where both fire safety and structural integrity are paramount.</p><h3><strong>Key characteristics of MgCarbonit91:</strong></h3><ul><li>Self-extinguishing for enhanced fire safety</li><li>Excellent casting and thixomolding process compatibility</li><li>Strong mechanical performance</li><li>Lightweight—approximately 33% lighter than aluminum</li><li>Suitable for high-risk applications</li></ul><h3><strong>Typical applications include:</strong></h3><ul><li>Battery housings</li><li>Aircraft seat backs and footrests</li><li>Display housings and table arms</li><li>Electronic enclosures and control boxes</li></ul><h2><strong>Innovation That Protects and Performs</strong></h2><p>By integrating MgCarbonit91 into its thixomolding operations, <a href="https://www.dynacast.com/en-us/locations/dynacast-austria">Dynacast Austria</a> is furthering its commitment to innovative materials that offer both performance and protection. As safety regulations grow more stringent and demand for lightweight metals continues to rise, MgCarbonit91 stands out as a next-generation alloy helping to shape the future of precision magnesium manufacturing.</p>

Discover how Dynacast's magnesium alloys achieve fire resistance, offering lightweight and safe solutions for advanced engineering applications.

Fireproof Magnesium Alloy Explained | Dynacast

This article introduces MgCarbonit91, a groundbreaking fire-retardant magnesium alloy used in Dynacast Austria's advanced thixomolding process. Readers can expect to learn how this material achieves a rare combination of lightweight strength, fire safety, and excellent moldability, making it ideal for high-performance applications in aerospace, electronics, and energy storage.

What Makes This Magnesium Alloy Fireproof?

<h4>All the benefits, none of the drawbacks</h4><p>There’s nothing better than sitting in the sun on a gorgeous deck. Properly maintained, a deck is an extension of your living space and an asset to any property. But as any deck owner knows: they can be a lot of work. Year-in, year-out, wooden decks demand regular maintenance—from resurfacing to varnishing. And if they don’t get it, they can become dangerous eyesores.</p><p>Of course, until now, wood has always been the default material used for decks. But not any longer if SigmaDek has anything to do with it. We spent some time with Brian Boettger, VP Product Development to find out more.</p><h4>Wanted: A metal-tile maker</h4><p>Butlers had seen Giles Miller’s work and wanted a brass finish for its café counter. The designers had produced a brass finish on ceramic tiles before, but they were worried ceramic wouldn’t survive the demands of a busy airport (where bags and luggage trolleys can deliver quite a pounding). So they thought of making metal tiles and started looking at metal manufacturing processes.</p><p>What they wanted was a 40mm-square metal tile with a chamfered face, and with one corner 20mm higher than the opposing diagonal—so when it’s rotated the light catches it in different ways. “When we started looking for a manufacturer there were a few other metal-casting companies but <a href="/about-us/company-overview" target="_self">Dynacast</a> was the most helpful,” says the designer Kirstie Little, “and the only one able to make the thousands of tiles we needed in the short lead-time we had.”</p><h3>From drawing board to café counter</h3><p>The designers made a trip to Dynacast’s UK plant in Welshpool, Wales, where sales manager John Jackson, who, like the rest of the sales team, is also an experienced engineer, gave them a factory tour. “We showed John the drawings and he was really helpful about the processes and what can and can’t be done,” says Kirstie. “He told us how to get the right finishes and how the tiles could be fixed on with a screw system at the back, as they were a bit too heavy to be stuck on. Having John involved right from the start meant everything went a lot quicker.”</p><p>For John this was an intriguing project. He knew zinc would be the best metal for the casting as it’s good at taking surface finishes. He also knew the client wanted a uniform brass finish, so after the initial copper coat, he recommended a nickel plating to give a white surface that would take the brass layer well on top.</p><p>The tiles were to be fixed onto panels by Giles Miller in its production space before being sent off to the client for installation. The assemblers needed to be able to take any tile out of the box and know the spacing would be absolutely consistent, so it was vital there was no machining variation between the tiles. Dynacast also ensured the plating was even and didn’t build up on sharp edges and corners. No machining marks were allowed to ruin the finish. And a stringent right-first-time approach meant there was no need for subsequent trimming or polishing.</p><h3>A showcase product</h3><p>Thanks to great communication between the client, Dynacast and the plating subcontractor, the project was delivered on time in just seven weeks. Kirstie says that Butlers “absolutely loved” the result and they’re in talks about another potential project. At the same time the die cast metal tiles are an important extension of Giles Miller’s product range and the designers have already been chatting to John about other shapes and different finishes such as antique brass and black nickel.</p><p>And this unusual project has also given John Jackson—and Dynacast—a new way of showing people what can be done with <a href="/metals/zinc" target="_self">zinc die casting</a> and <a href="/additional-capabilities/surface-finishes-and-plating" target="_self">surface finishes</a>. “If you can deliver something as cosmetically challenging and visually stunning as this in such a short space of time, it really does open up new opportunities,” he says. “I hadn’t thought of using zinc die casting in this way before, and this project shows that we are only limited by our imagination in how we apply it.”</p>

Explore how advanced die cast plating techniques improve surface quality, durability, and performance.

Enhance Die Cast Plating for Superior Finish

Explore how Dynacast's expertise in zinc die casting and superior plating solutions delivered stunning, uniform brass finishes for a high-profile café counter project, showcasing the versatility and aesthetic potential of metal tiles.

Superior Die Cast Plating

<p>The <a href="/locations/dynacast-lake-forest" target="_self">Dynacast Lake Forest facility</a> offers a wide range of secondary operations including CNC machining, tapping, reaming, and drilling.</p>

Dynacast Lake Forest Secondary Operations

The Dynacast Lake Forest facility offers a wide range of secondary operations including CNC machining, tapping, reaming, and drilling.

Enterprise Technology

Enterprise Technology Leaders Choose Dynacast To Help Achieve Key Goals

Dimensional Accuracy

Rapid Production

Material Variety

High Production Rates

Industry Leading Certifications

A Look At
Enterprise Technology Applications

REAL RESULTS

Enhanced Performance for LiDAR Sensor Housings

BEYOND THE BASICS

Elevate Your Knowledge About Die Casting for Enterprise Technology

Article

Case Study

Video

Global Reach, Local Expertise

Interested in starting your die casting journey?

Enterprise Technology

Enterprise Technology Leaders Choose Dynacast To Help Achieve Key Goals

Dimensional Accuracy

Rapid Production

Material Variety

High Production Rates

Industry Leading Certifications

A Look AtEnterprise Technology Applications

REAL RESULTS

Enhanced Performance for LiDAR Sensor Housings

BEYOND THE BASICS

Elevate Your Knowledge About Die Casting for Enterprise Technology

Article

Case Study

Video

Global Reach, Local Expertise

Interested in starting your die casting journey?

A Look At
Enterprise Technology Applications