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<p>When miniaturization meets industrial-grade durability, the stakes are high. For SICK, a global leader in sensor technology, designing the <strong>picoScan100 2D LiDAR sensor</strong> meant pushing the limits of engineering—requiring a manufacturing partner to deliver precision, complexity, and reliability in one of the smallest, most sensitive components on the market.</p><h2><strong>The Challenge: Tiny Sensor, Big Demands</strong></h2><p>SICK's picoScan100 posed a unique engineering dilemma. The <strong>sensor housing</strong> had to be <strong>incredibly small</strong>, <strong>mechanically intricate</strong>, and <strong>tolerant to the rigors of industrial environments</strong>—all while ensuring <strong>exact internal tolerances</strong> for stable lens placement. Complicating matters further were <strong>minimal draft angles</strong> and the necessity for <strong>flawless shot accuracy</strong>, making traditional manufacturing approaches difficult and error prone.</p><h2><strong>The Solution: Precision Engineering from Concept to Completion</strong></h2><p>Recognizing the sensor’s complexity, SICK turned to Dynacast for a solution that would combine <strong>engineering expertise, process control, and collaborative innovation</strong>.</p><p><strong>1. Collaborative Design Support</strong></p><p>Dynacast was brought in early to help optimize the housing’s geometry, ensuring <strong>manufacturability without compromising function</strong>. This proactive partnership allowed design and production to align from day one.</p><p><strong>2. Simulation-Driven Precision</strong></p><p>By leveraging simulation software alongside deep die casting expertise, Dynacast fine-tuned the tooling and process flow—<strong>mitigating risks</strong> before production began.</p><p><strong>3. Precision Microcasting</strong></p><p>With a focus on <strong>gating and overflow design</strong>, Dynacast achieved flawless mold filling—ensuring dimensional integrity and consistent part quality at micro scales.</p><h2><strong>The Results: Flawless Execution, Satisfied Partners</strong></h2><p>SICK’s expectations were not only met—they were exceeded.</p><ul><li><strong>Seamless Integration</strong>: The sensor housing was implemented smoothly, <strong>without the need for post-production corrections.</strong></li><li><strong>Perfect Performance</strong>: Every unit met the stringent performance requirements essential to the LiDAR system’s functionality.</li><li><strong>Customer Satisfaction</strong>: SICK lauded the collaboration and outcome, with Dynacast recognized for a well-executed strategy that delivered value from start to finish.</li></ul><p><strong>“[Dynacast delivered] smooth implementation of the entire project without additional corrections.”</strong> – <em>SICK</em></p><p><strong>“SICK was a very satisfied customer thanks to our implementation strategy.”</strong><br />– <em>Markus Verini, Business Development Manager, Dynacast Europe</em></p>

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Discover how Dynacast provided high-precision die-cast components for SICK’s LiDAR sensors, ensuring optimal performance and reliability.

Precision Die Casting for SICK’s LiDAR Sensor | Dynacast

Discover how Dynacast partnered with SICK to deliver flawless, high-precision sensor housing for the picoScan100 2D LiDAR—overcoming extreme design challenges through early collaboration, simulation-driven engineering, and micro-scale casting expertise.

How Dynacast Delivered Precision for SICK’s LiDAR Sensor

<h2><strong>The Challenge: Plant Closure Opens a Complex Mission</strong></h2><p>When a long-established plant shut down, a leading player in the security products industry was faced with an urgent and complicated transition. The facility's aging infrastructure, high labor costs, and inefficient tooling utilization had made in-house production unsustainable. With most of the tooling contributing minimally to overall production spend, the decision was made to relocate dozens of tools—an ambitious move requiring speed, coordination, and technical precision.</p><p>But the road ahead wasn’t simple. Rising cost pressures, logistical strain from shipping dozens of tools monthly, and unclear tooling documentation posed real threats to success. On top of that, inconsistent sampling protocols and missing information for secondary operations risked slowing everything down.</p><h2><strong>The Solution: A Smart Shift to Efficiency and Control</strong></h2><p>Dynacast’s focus was not just on moving tools—it was on optimizing them for better performance and building a foundation for long-term value.</p><p>Dynacast brought deep <strong>expertise in precision casting</strong>, using an engineering-first approach to ensure every part was thoughtfully designed and accurately cast for optimal performance. This technical rigor was matched by <strong>speed without compromise</strong>—the team acted swiftly to meet tight timelines without ever cutting corners, maintaining the highest quality standards throughout. What truly set the project apart, however, was the <strong>partnership dynamic</strong>.</p><h2><strong>The Implementation: Prioritizing Medium-to-Low Volume Parts</strong></h2><p>Thanks to compatibility with the customer’s existing equipment platforms, the Dynacast team was able to integrate the transferred tools with minimal disruption—often getting machines running within a day or two. Dynacast focused efforts where it mattered most: medium-to-low volume parts that offered the greatest strategic value, while also keeping future high-volume opportunities in view.</p><h2><strong>Capabilities That Count</strong></h2><p>The equipment used at Dynacast represented a major upgrade from the aging machines of previous suppliers. Our ability to build both tools and machines in-house gave the team unique control over quality and lead times. And when added flexibility was needed, our collaboration with global teams—including engineering support from Asia—ensured nothing slowed progress.</p><h2><strong>The Results: Partnership, Performance, and Future Potential</strong></h2><p>Weekly check-ins, pilot runs, and a commitment to shared success laid the groundwork for a lasting strategic relationship. By avoiding supply chain disruptions during a critical transition, Dynacast not only ensured continuity but also improved tooling performance—extending tool life and setting the stage for future growth and opportunities.</p><p></p>

Learn how Dynacast managed a complex tooling move after a plant closure, ensuring uninterrupted production and timely delivery.

Tooling Transfer After Plant Shutdown | Dynacast Case Study

In this case study, you'll see how Dynacast tackled the urgent challenges of a plant closure for a major security products company—moving dozens of tools quickly and precisely while improving overall efficiency. You'll learn how their engineering-first approach and close collaboration helped turn a complex transition into a long-term strategic win.

How Dynacast Orchestrated a Complex Tooling Move

<h2><strong>The Challenge: A Race Against Time and Quality</strong></h2><p>Faced with new federal incentives aimed at reshoring production to the U.S., a leading solar mounting system manufacturer encountered a major roadblock. Their previous die casting supplier couldn’t deliver the speed, quality, or production volume needed to capitalize on the opportunity. Poor production output, neglected tool maintenance, and lack of support put both the project timeline and valuable tax incentives at risk.</p><h2><strong>The Objective: Onshore, Scale, and Elevate Quality</strong></h2><p>The customer’s goals were clear: move production stateside, improve component quality, and ramp up capacity to meet a growing market. But meeting these targets meant overcoming the obstacles of a struggling supplier and executing a tooling transfer that wouldn't disrupt the manufacturing timeline.</p><h2><strong>The Solution: A Strategic Partnership Built for Performance</strong></h2><p>The Dynacast team quickly developed a plan to bring the customer's program back on track.</p><p>Dynacast prioritized a <strong>rapid, quality-driven onshoring</strong> process, recognizing the urgency of the situation. The team executed a seamless tooling transfer and ramped up production, enabling the immediate delivery of high-quality parts from day one.</p><p>In addition, <strong>supply chain simplification</strong> was a key focus. Dynacast offered a range of value-added services, including in-house assembly, custom fixtures, and specialized packaging.</p><h2><strong>Engineering in Action: From On-Site Visits to Dynacast Lake Forest</strong></h2><p>The success of this transition hinged on careful engineering and collaboration:</p><ul><li><strong>A Hands-On, Collaborative Approach</strong>: Dynacast’s Lake Forest engineering team worked closely with the customer’s technical staff to understand exact product and tooling requirements. The process began with an on-site review at the outgoing supplier’s facility and continued with a detailed inspection once the tools arrived at Dynacast.</li><li><strong>Expert Tool Refurbishment &amp; Integration</strong>: The tools were thoroughly cleaned, refurbished, and, where needed, modified to suit Dynacast’s production environment. This careful preparation ensured a smooth handoff with minimal production disruption.</li></ul><h2><strong>The Results: Onshoring Success with Room to Grow</strong></h2><p>The solar manufacturer successfully moved production to the U.S., qualifying for tax incentives and dramatically improving part quality. Beyond immediate gains, the company also laid the groundwork for broader reshoring initiatives.</p>

Discover how a solar company leveraged U.S. tax incentives by relocating manufacturing domestically with Dynacast, enhancing efficiency and cost savings.

Onshoring Solar Manufacturing | Dynacast Case Study

Discover how Dynacast helped a solar mounting system manufacturer overcome critical supplier issues just in time to meet federal reshoring incentives. You'll see how fast, high-quality production, smart engineering, and close collaboration enabled a seamless transition to U.S.-based manufacturing—paving the way for long-term growth and success.

How This Solar Company Capitalized on Tax Incentives By Onshoring

<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 zinc die cast parts, 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 tooling transfer 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 engineering team 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>

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

<h2>DFM for Aluminum Die Castings</h2><p></p><p>When you think of an outdoor deck, the first thing you think of is probably wood. But what if there’s a better option? Something that won’t degrade, warp, rot or require regular annual maintenance? The innovators at Calgary-based SigmaDek knew there had to be a better way and approached Dynacast to help them find it.</p><h4>All the benefits, none of the drawbacks</h4><p>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>A collaboration of experts</h4><p>In order to achieve this dream, Brian said they recognized “we needed ‘best in class’ partners if we were to build the business to its full potential. We identified Dynacast as that partner and reached out to them very early on.”</p><h3>The advantages of aluminum</h3><p>However, in order to manufacture the precision components SigmaDek required, they needed die casting expertise which is when they turned to Dynacast. “Our expertise is not in die cast, so having the opportunity to work with the team at Dynacast was invaluable. They had a complete understanding of the process and its various idiosyncrasies to help in the fine-tuning of the design of each part,” said Brian.</p><h3>Rising to the challenge</h3><p>In order to deliver parts which provided the strength needed but did not add to the price, Dynacast’s engineers improved the design for manufacturability (DFM) for more than 30 unique die cast parts.</p><p>Changes included the elimination of undercuts, the addition of draft angles to some features, wall thicknesses, structural ribs, gates, runners, and overflows. By making the parts easier to die cast, the DFM modifications produced a significant cost benefit. Savings came in the form of less complex tooling, faster cycle times, and fewer secondary machining operations.</p><h3>Introducing a world first</h3><p>The result? The world’s first fully fabricated, non-wood decking system which meets all SigmaDek’s safety and maintenance goals.</p><p>Strong, sustainable and designed to enhance the beauty of any home, SigmaDek is the result of the finest minds in die casting and decking working together to achieve a world first. In the words of Brian Boettger, working together with Dynacast meant “we are able to deliver a product to the end-user which we are confident meets or exceeds anything else in the marketplace.”</p>

Explore how applying DFM to aluminum die castings ensures optimal performance and cost-effective results.

DFM for Aluminum Die Castings: Best Practices

DFM for Aluminum Die Castings

<p>Mold release is a critical step in the die casting process, ensuring that precision metal components eject from the die effortlessly and free of defects.</p><h2>What is Mold Release?</h2><p>Mold release, also known as die spray or die lubricant, is a liquid that is applied to the steel mold before each shot of molten metal. The liquid evaporates when it comes into contact with the hot steel, leaving behind a thin, lubricated coating. This coating helps to prevent the metal from sticking to the mold, making it easier to eject.</p><h2>Why is Mold Release Important?</h2><p>Mold release is important for several reasons:</p><ul><li>It prevents the metal from sticking to the mold, which can cause defects in the finished part.</li><li>It helps the metal to flow more freely into the mold, resulting in a more accurate casting.</li><li>It reduces the amount of force required to eject the part from the mold, which can extend the life of the mold.</li><li>It can improve the cosmetic finish of the part.</li></ul><h2>Types of Mold Release</h2><p>There are many different types of mold release available, each with its own advantages and disadvantages. The type of mold release that is best for a particular application will depend on the type of metal being cast, the complexity of the part, and the desired finish.</p><ul><li>Water-based mold releases are the most common type. They are relatively inexpensive and easy to use. However, they can be less effective than other types of mold releases in preventing porosity.</li><li>Oil-based mold releases are more effective at preventing porosity than water-based mold releases. However, they are more expensive and can be more difficult to use.</li><li>Silicone mold releases are a good choice for parts that require a high-quality cosmetic finish. They are also effective at preventing porosity. However, they can be more expensive than other types of mold releases.</li></ul><h2>Mold Release Concerns</h2><p>There are two main concerns that customers typically have about mold release:</p><ul><li>Will mold release cause porosity?</li><li>Is mold release safe for medical and surgical applications?</li></ul><p>Porosity is a natural occurrence in the die casting process. However, the amount of porosity can be minimized by using the right type and amount of mold release. Dynacast works with customers to select the mold release that is best suited for their specific application.</p><p><br />Mold release can be safe for medical and surgical applications if it is properly applied and the part is properly cleaned after casting. Dynacast works with customers to ensure that their mold release is safe for their specific application.</p><h3>Dynacast is an ISO 13485 Certified Die Casting Manufacturer</h3><p>Dynacast is an ISO 13485 certified die casting manufacturer. This means that we have met the highest standards for quality and safety in the medical device industry. We use only the highest quality mold releases that are safe for medical and surgical applications.</p><h3>Contact Dynacast Today</h3><p>If you are looking for a die casting manufacturer that can provide you with the highest quality parts, contact Dynacast today. We have over 50 years of experience in the die casting industry and we have a team of experts who can help you with every step of the process.<br />We will work with you to select the right type of mold release for your application and we will ensure that it is applied correctly. We will also work with you to ensure that your part is properly cleaned after casting.</p>

Manufacturing employee operating equipment in Peterborough

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Learn how mold release agents enhance die casting by preventing adhesion, improving part quality, and extending tool life in Dynacast's manufacturing processes.

Utilizing Mold Release in Die Casting Processes | Dynacast

See the essential role of mold release in the die casting process, detailing its types, benefits, and concerns to ensure defect-free and high-quality metal components.

Utilizing Mold Release During the Die Casting Process

<h1>An Introduction to Precision Die Casting</h1><p>Dynacast, a Form Technologies Company, is a global manufacturer of precision, engineered metal components. Utilizing proprietary die cast technologies, we offer robust solutions to many industries including automotive, consumer electronics, and healthcare. </p><p>Every organization we work with benefits from over 80 years of experience, innovation, and techniques that have redefined the manufacturing industry. Dynacast operates 21 manufacturing facilities in 16 countries, and consistently delivers value through engineering expertise, efficient operations, and Advanced Quality Planning systems.</p><p>Join us for the initial installment of the Dynacast Metal Solutions Webinar Series - Europe. In this webinar, our team will cover:</p><ul><li>Material options</li><li>Die casting technology</li><li>Innovations in die casting showcase</li><li>Case studies</li><li>And more!</li></ul><p></p>

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Discover Dynacast's proprietary die casting technologies and how high-quality engineering, tooling, and process controls contribute to superior components.

An Introduction to Precision Die Casting | Dynacast Webinar

Join us for the Dynacast Metal Solutions Webinar Series - Europe as we explore material options, die casting technology, and innovative solutions in precision die casting, drawing on over 80 years of expertise to deliver cutting-edge insights and case studies. 

An Introduction to Precision Die Casting

<h1>Work Smarter. Not Harder.</h1><p>Design for manufacturing (DFM) is a Dynacast core methodology that ensures your die cast parts perform to specification and require the minimum of secondary operations, which can often represent as much as 80% of the component cost. In other words, DFM enables design engineers to work smarter, not harder.</p><p>Modifying your part design to take advantage of the die casting process not only enables you to fully leverage the efficiencies of die casting, but can also better suit your business needs. Learn about the benefits of die casting and optimizing your component for manufacturability in our webinar, where we’ll cover:</p><p>Design for manufacturing core concepts</p><ul><li> Eliminating inefficiencies</li><li>Component optimization for lowered part cost</li><li>Extending tool life</li><li>The importance of early engineer involvement, and more!</li></ul><p><strong>Fill out the form to download our free on-demand webinar.</strong></p><p></p>

Learn how to reduce component costs and optimize designs with our on-demand webinar on Design for Manufacturing (DFM). 

Removing Cost in the Design Stage | Dynacast Webinar

Discover how Design for Manufacturing (DFM) can streamline your design process, reduce component costs, and enhance tool longevity in our on-demand webinar, where we'll explore core DFM concepts, inefficiency elimination, and the benefits of early engineer involvement. 

Removing Cost in the Design Stage

<h1>Nickel-Free Coating for Die Castings</h1><p>Nearly every die cast material needs a coating for corrosion purposes. Typically for components that have cosmetic finishes, the best under layer for finishing is nickel. It has great adhesion properties and acts a barrier for the skin. To give you an idea, we would cast the component and then put a layer of nickel plating on the part to create a foundation for the cosmetic coating whatever that may be, satin chrome, PVD, etc. </p><p>With the continued rise of wearables and fitness trackers, the concern is when the coating would scratch off leaving a nickel to skin contact that creates challenges for die casters and suppliers in the consumer electronics industry. Buyers with sensitive skin can develop a rash from metal wearables containing nickel. Resulting in bad press for your business. With a 15% of Dynacast’s customers coming from consumer electronics, our Dynacast Singapore facility set out to find a solution.</p><h2>Highly-Cosmetic Nickel-Free Plating Options</h2><p>For years, to combat the allergic reaction caused by the nickel to skin contact, companies would make the components using MIM with stainless steel or machine it from aluminum or steel billet. Depending on the complexity of the component, die casting could be the more economical choice over MIM and it is almost always more cost-effective than machining from billet. We are talking about saving several dollars on part cost, which adds up very quickly with high volume runs. But businesses have to do what is necessary to prevent any sort of legal liability from an unhappy customer.</p><p><strong>Enter Dynacast Singapore with a great alternative. </strong>Nickel-free plating options for die castings that won’t leave consumers with awful skin rashes. This coating is used as the base layer before the cosmetic finish and it can be used on almost any material—though it works best on aluminum and zinc alloys. This gives design engineers the ability to design more freely.</p><p>The ability to design and make zinc and aluminum components for wearable market and offer them allergy free products has opened up a plethora of opportunities in the consumer electronics industry. These die casting options are lower in cost than their current components.</p><p><strong>This coating is also suitable for use in the virtual reality and medical device markets. With over 18 different color options, the possibilities for this coating are endless.</strong></p>

Explore Dynacast's nickel-free coating options for die cast parts, offering corrosion resistance and aesthetic appeal without nickel-related sensitivities.

Nickel-Free Coating Solutions for Die Castings | Dynacast

A nickel-free plating option for die castings that provides a cost-effective, allergy-safe solution for consumer electronics, medical devices, and other applications, offering enhanced design flexibility and a variety of cosmetic finishes. 

Nickel-Free Coating for Die Castings

<h2>Multi-Slide. Multi-Solution. Die Casting.</h2><p>Ask any engineer and they’ll tell you; great tool design is critical to the success of die cast components. One of the best options for creating small, complex parts is through the use of multi-slide tooling. Multi-slide is designed to use four (or more) perpendicular slides in the tool, thus creating more complex and accurate castings. </p><p>Multi-slide offers a number of unique advantages, including:</p><ul><li>Net shape first time, eliminating secondary operations like assembly and machining</li><li>Complex geometry and tight tolerances at high speed for world-class productivity and lower total costs</li><li>Minimum part-to-part variation compared to standard multi-cavity dies</li><li>More compact tools that are less prone to parting-line variation and its negative effect on the ﬁnished part’s dimensional tolerances</li></ul><p><strong>Multi-Slide. Multi-Solution. Die Casting.</strong></p><p><strong>When:</strong> On-Demand</p><p><strong>Presenters:</strong> Sergio Perino and Marc Boettcher </p><p></p><p></p>

Learn about achieving net shape accuracy, handling complex geometries, reducing part-to-part variation, and leveraging compact tooling for optimal results. 

Dynacast Webinar | Multi-Slide. Multi-Solution. Die Casting.

Explore the benefits of multi-slide tooling for die casting, including net shape accuracy, complex geometry, minimal part-to-part variation, and compact tools, in our on-demand webinar with Sergio Perino and Marc Boettcher. 

Multi-Slide. Multi-Solution. Die Casting.

Dynacast offers two primary die-casting methods: the hot chamber and cold chamber processes. The hot chamber process uses a molten metal supply directly connected to the die-casting machine, making it ideal for metals with low melting points, such as zinc and magnesium, and enabling faster production rates. In contrast, the cold chamber process involves manually pouring molten metal into the machine from an external furnace, making it suitable for metals with higher melting points, such as aluminum, to ensure more precise control over the casting process.

Hot Chamber vs. Cold Chamber Die Casting Process

<h2>Higher quality and cost savings with die casting</h2><p>The die casting process is ideal for producing extremely complex components at high volumes. While other manufacturing processes like machining, stamping, or spin casting may offer quality or volume, die casting delivers both. How?</p><p>The key lies in world-class process controls and superior automation.</p><p>We’ve covered the foundations of die casting technologies, and now we want to showcase our state-of-the-art processes and automation in real time. With advanced automation, Dynacast delivers reliability, cost savings, and improved part performance.</p><p>Discover how our automation reduces risk, cuts costs, and accelerates production by watching our on-demand webinar, featuring videos of our technology in action. In this webinar, we cover:</p><ul><li>Automated die casting processes</li><li>How automation removes added costs and risk</li><li>How automation speeds up component delivery</li><li>And more!</li></ul><p>Fill out the form to access our free on-demand webinar.</p><p><strong>For the best experience, please use Google Chrome, Safari, or Firefox. This webinar will be presented in English.</strong></p><p></p>

See die casting technology in action with a live virtual demo showcasing processes, tools, and production capabilities.

Live Die Casting Tech Demo | Dynacast

Join this webinar showcasing how advanced automation in die casting enhances quality, reduces costs, mitigates risks, and accelerates production through real-time demonstrations of cutting-edge processes. 

Die Casting Technologies in Action: Virtual Demonstration

<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 aluminum alloys 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>Automotive</h3><p>Unlike conventional hot-chamber die casting, which utilizes a two-part tool, multi-slide 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></p>

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

<p>High pressure die casting is a fast, repeatable process that delivers quality metal components, every time—but only if your component is designed properly. There are many factors that go into a successful design for high-volume manufacturing and our team of engineers helps thousands of customers each year successfully launch new projects.</p><h1>What is Injected Metal Assembly?</h1><p><em>There are many different methods of joining metal and other materials, and depending on your industry, there certain considerations that determine the most effective method of assembly. If you’re currently crimping, soldering, staking, or welding components together, injected metal assembly (IMA) could be a more efficient and reliable option for you.</em><br />What is injected metal assembly?</p><p>The IMA process is a type of Insert Molding that uses a molten zinc alloy to join similar or dissimilar components together and create a singular assembled part that is strong, flash-free, and repeatable. With production rates up to 1,000 parts an hour, IMA adhesion ensures consistent higher quality parts while keeping manufacturing costs low.</p><p><strong>The uneven heating and cooling of the welding process produces brittle joints that are vulnerable to stress. As a result, their fatigue strength is far less than that of components joined by IMA.</strong></p><h3>How does IMA work?</h3><p>First, the components that need to be assembled are placed into the machine in a custom designed casting tool. These custom tools are able to accommodate components of various shapes, sizes, and materials.</p><p>Next, the tool closes and precisely aligns to holds the components in their precise position while the molten alloy is injected into the cavity at the intersection of the components. The alloy—usually zinc for its high strength, dimensional stability, and load-bearing characteristics—solidifies in a fraction of a second and produces a strong, permanent lock between the components. Finally, the tool opens and the assembled part is ejected from the die. The ejected component is flash-free, requires no secondary operations, and is stronger than conventionally joined metal components.</p><p><em>When the zinc alloy is injected, it fills the cavities in the custom tool and hardens to create a permanent bond between the components.</em></p><p>In addition to being high in strength and stability, zinc alloys are predictable in their flow and shrinkage characteristics, enabling our designers to calculate with high accuracy the final dimension of the injected metal joint. This allows for exacting tight tolerances to improve the overall functionality of the part.</p><h3>What is the required volume for the IMA process to be viable?</h3><p>Dynacast is capable of running varied volumes, down to 5,000 pieces a year if need be and up to 3 to 4 million parts per year with the help of automation and robotics. The volume of production is largely dependent upon the needs of the customer.</p><h3>When joining metal and a material like plastic, how do you keep the plastic from melting when it comes in contact with the injected molten metal?</h3><p>With IMA, we are able to hold the die closed for up to a whole second, depending on the fragility of the plastic, and allow the heat to dissipate in the water-cooled tool. In addition to this cooling process, the low melting point of injected metal prevents thermal degradation of the parent materials.</p><h3>Can you prototype an IMA part?</h3><p>Yes. While we cannot create a complete part before production begins, Dynacast can build simple “soft tooling” and create part-specific cavity blocks to insert into the tooling for a low production concept. Dynacast also offers a pull-ahead system where we build the tool to a certain point, and if parts produced are accepted by the customer, we complete the tool.</p><h3>How does IMA reduce cost?</h3><p>IMA reduces cost by cutting production time and eliminating the need for secondary operations. While processes like welding, soldering, and crimping are often very labor intensive, IMA has the potential to be fully automated. When part is ejected, flash-free and permanently bonded, it is ready for use.</p><h3>What are major markets served by the IMA process?</h3><p>The IMA process serves virtually any industry and any application. Automotive, telecommunications, electronic components, hardware and appliances, industrial controls, and military industries often utilize parts crafted by the IMA process.</p><p><strong>Would you like to learn more about the IMA process and practical applications? Fill out the form to download our free webinar!</strong></p>

Discover Dynacast's IMA process—a cost-effective method using molten zinc to join components, enhancing strength and reducing assembly steps.

What Is Injected Metal Assembly? | Dynacast Article

Injected Metal Assembly (IMA) is a high-efficiency manufacturing process that uses molten zinc alloy to permanently join metal components with precision, creating strong, flash-free parts with reduced production costs and enhanced reliability compared to traditional methods like welding and soldering.

What is Injected Metal Assembly?

<p>Download <strong>Voices from the Design World</strong> to see what your peers have to say about:</p><ul><li>The role technology has played in advancing design</li><li>Insights about emerging design engineering practices</li><li>Common frustrations with manufacturing partners, and the best ways to address them</li><li>Advice for keeping pace with change – and staying ahead</li></ul><p>And much more. Enter your details to get instant access.</p><p></p><p>Please fill out the form to access your copy of the white paper. </p>

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Explore key insights from the "Voices from the Design World" report on technology, design practices, and overcoming challenges with manufacturing partners. 

Voices from the Die Cast Design World | Dynacast White Paper

Explore insights from engineers on the evolving design engineering industry, including the impact of technology, emerging practices, and strategies for overcoming common challenges with manufacturing partners.

Voices from the Design World

<p>Explore Dynacast Peterborough's wide range of die cast secondary operations, including CNC machining, welding, manual processes, vision sorting, media tumbling, reaming, riveting, staking, drilling, tapping, CNC milling, and in-house plating. </p>

Explore Dynacast Peterborough's wide range of die cast secondary operations, including CNC machining, welding, manual processes, vision sorting, media tumbling, reaming, riveting, staking, drilling, tapping, CNC milling, and in-house plating. 

Secondary Operations In-House Capabilities

<h1>Design Tips for Improved Die Casting</h1><p>Die casting is a versatile manufacturing process capable of producing a wide range of parts from various metals. To optimize part design and achieve optimal results, consider these essential tips.</p><h2>Die Casting Variables</h2><p><strong>Draft:</strong>&nbsp;Incorporating draft, a slight taper on part walls, is crucial for easy casting removal and to compensate for shrinkage. Aim for a draft angle of ¼ to 1 degree per side, adjusting as needed based on alloy and process.</p><p><strong>Fillets and Radii:</strong>&nbsp;Generous fillets and radii enhance part strength, improve metal flow, and simplify finishing. Implement them whenever possible.</p><p><strong>Ribs and Bosses:</strong>&nbsp;While ribs and bosses increase part strength, ensure they blend seamlessly with fillets and radii to avoid sharp corners. Apply draft to non-critical surfaces.</p><p><strong>Pockets:</strong>&nbsp;Reduce part weight and cycle time by incorporating pockets into solid sections. Maintain proper draft and radii for optimal results.</p><p><strong>Optimizing Material Flow:</strong>&nbsp;Facilitate metal flow by designing parts with smooth corners and uniform sections. While challenging in some cases, minimize restrictions like long slots and maximize flow with round holes.</p><h3><strong>Additional Considerations</strong></h3><p>Explore the full potential of the die casting process by incorporating features like logos, textures, integrated fasteners, and embossed part numbers. Dynacast’s 4-slide die casting process offers even greater flexibility.</p><p>Dynacast provides a comprehensive design for manufacturing&nbsp;(DFM)&nbsp;service to help optimize your part design for die casting and cost-effectiveness.</p>

Enhance die casting efficiency and part quality with Dynacast's expert design tips, focusing on manufacturability and cost-effective production.

Design Tips for Improved Die Casting | Dynacast Article

See essential design tips for optimizing die casting parts.

Design Tips for Improved Die Casting

<h1>Dynacast Surface Coatings: A Comprehensive Guide</h1><p>Is your part in need of a surface coating but uncertainty about the best option prevails? Dynacast offers a diverse range of approximately thirty coatings, from chrome to electroless nickel and beyond. This comprehensive guide explores several key coating types, their characteristics, and suitable applications.</p><p>While this blog covers many options, Dynacast constantly introduces new surface coating solutions based on customer demands. If you require a coating not listed here, please contact our team.</p><p>For detailed information on specific surface finishing options, consult with one of our design engineers.</p><h2>Chrome vs. Chromate</h2><p>Before looking into specific coatings, it's essential to differentiate between chrome and chromate. Chrome, derived from chromium, is an electroplated finish often associated with a shiny, metallic appearance, as seen on automobiles. Chromate, conversely, is a corrosion-resistant conversion finish rather than an additive coating. Dynacast provides numerous options for both chrome and chromate finishes.</p><h3>Chrome Plating</h3><p><strong>Bright Chrome:</strong>&nbsp;This mirror-like finish is familiar from automobiles, toys, and furniture. It offers corrosion protection, good wear life, and aesthetic appeal.</p><p><strong>Satin Chrome:</strong>&nbsp;Similar to bright chrome but with a duller finish. Both finishes involve rack plating with layers of copper, nickel, and chrome.</p><h3>Chromate with Zinc</h3><p>Zinc coatings are soft, decorative, and corrosion-resistant, protecting the base metal through sacrificial corrosion. Chromate application enhances corrosion protection.</p><ul><li><strong>Clear Chromate with Zinc:</strong>&nbsp;Exhibits a slightly iridescent blue hue.</li><li><strong>Yellow Chromate with Zinc:</strong>&nbsp;Imparts a yellow color to the finished part.</li><li><strong>Black Chromate with Zinc:</strong>&nbsp;Provides a black finish.</li></ul><h3>Chromate without Zinc</h3><p>Black chromate without zinc is an inexpensive type of chromate. It’s typically used for parts that do not require a high amount of corrosion resistance. The coating goes directly onto a zinc die cast part. Yellow chromate parts are chemically milled and then chromated. This gives the part a dull finish. Both of these coating options are very thin and contribute no measureable thickness to the overall coating.</p><h3>Additional Chromates</h3><ul><li><strong>Olive Drab Chromate:</strong>&nbsp;Features a dark green finish and withstands 150 hours to white corrosion.</li><li><strong>Trivalent Chromate:</strong>&nbsp;Offers similar properties to traditional chromate without containing hexavalent chromium. Environmentally friendly with a bright blue color, exceeding automotive specifications.</li></ul><h3>Nickel Plating</h3><p>Nickel plating, characterized by a yellowish-white color and hard reflective finish, excels in wear resistance, solderability, and dimensional repeatability. Typically applied over copper on die castings, it also serves as a base layer for chrome plating.</p><ul><li><strong>Bright Nickel:&nbsp;</strong>The most common type but exercise caution with cold-forming due to potential ductility compromise.</li><li><strong>Watt's Nickel:&nbsp;</strong>Offers a satin finish and improved ductility, suitable for components requiring cold-forming.</li></ul><h3>Electroless Nickel</h3><p>Unlike electroplating, electroless nickel deposition does not require an electric current. This process yields exceptionally uniform coating thickness. It is widely used for its corrosion, wear, and abrasion resistance, along with ductility, lubricity, solderability, and hardness.</p><ul><li><strong>Low, Mid, and High Phosphorus:&nbsp;</strong>Varying phosphorus content influences properties.</li><li><strong>Black and Dark Blue Electroless Nickel:&nbsp;</strong>Primarily for decorative purposes.</li></ul><h3>Tin Plating</h3><p>Tin plating is ideal for components undergoing soldering during assembly. It offers excellent ductility, high solderability, and good surface coverage.</p><ul><li><strong>Matte Tin: Typically exhibits better solderability than bright tin.</strong></li><li><strong>Bright Tin: More commonly specified due to its superior appearance.</strong></li></ul><h3>Cobalt-Tin</h3><p>Resembling chrome in appearance and application, cobalt-tin involves copper/nickel plating followed by a cobalt-tin flash for a chrome-like finish. Known for its hardness and durability.</p><h3>Silver Plating</h3><p>Silver is valued for its low cost, despite tarnishing susceptibility to sulfur. It is primarily chosen for decorative, electrical conductivity, or thermal conductivity purposes. Offers high electrical and thermal conductivity, solderability, malleability, and ductility.</p><h3>Gold Plating</h3><p>Frequently used in electronics due to its low contact resistance, solderability, and wire bonding capabilities. Alloying with cobalt enhances hardness and wear characteristics. Gold plating is available in four types: pure gold, hard gold, electroless gold, and immersion gold. Refer to the surface finishes page for details.</p><h3>Cadmium Plating</h3><p>Offers exceptional corrosion protection, approximately double that of zinc. Commonly used in aerospace, marine, and saltwater environments.</p><h3>Brass Plating</h3><p>Primarily used for decorative purposes, brass plating can be applied in bright or satin finishes and oxidized for an antique look. A lacquer topcoat can enhance coating longevity.</p><h3>Chem Film</h3><p>Chem film, also known as a conversion coating, is specifically designed for aluminum die castings. The coating's color can range from dark golden brown to light yellow, depending on various factors. Importantly, chem film does not alter the part's dimensions. There are two primary types of chem film: Class 1A and Class III, which are detailed on Dynacast's surface finishing page.</p><h3>Black E-Coat</h3><p>Black e-coat is a paint coating electrically applied to enhance a part's appearance and protect its surface.</p><h3>Anodizing</h3><p>Anodizing creates a non-conductive, protective coating that seals the part. Commonly used types include clear and black anodize. The final color is influenced by the die casting alloy, with aluminum exhibiting minimal color change. Anodizing allows for various color dyeing options, with black, blue, and red being the most popular. Two classes exist: Class 1, the natural color without dye, and Class 2, dyed to a specified color.</p><h3>Polyurethane Paint</h3><p>Renowned for its exceptional durability, polyurethane paint is often recommended for outdoor or exposed parts. It can be applied in smooth or textured finishes and typically air-dries, though baking accelerates the process.</p><h3>Powder Coating</h3><p>Powder coating surpasses standard wet paints in terms of thickness uniformity and color consistency. The coating process involves curing at elevated temperatures, resulting in exceptionally tough finishes. Beyond its high hardness, powder coating is visually appealing, effectively conceals minor surface flaws, and delivers a durable, high-gloss appearance. Additionally, it is environmentally friendly, posing no air quality or hazardous waste concerns.</p><h3>Black Oxide</h3><p>Black oxide provides a protective, corrosion-resistant finish. While commonly associated with firearms, it also finds applications in spark plugs, furniture brackets, and mower blades. The black finish is chip-resistant and acts as an absorbent for oils or wax. Its economic nature, coupled with its ability to extend a part's service life and performance, makes black oxide a valuable coating option.</p>

Explore Dynacast’s surface finishing options, including chrome and chromate coatings, to enhance corrosion resistance and aesthetics of die cast components.

Surface Finishing Options for Die Cast Parts | Dynacast

Multi-slide die casting is a sustainable manufacturing process that offers environmental benefits.

Surface Finishing Options

<h1>Get your free white paper: Engineering Value: Balancing Design with Cost-Effective Production</h1><p>Get manufacturing costs down while staying true to design.</p><p>Design engineers who need to balance lower-cost parts with the integrity of their design have a new tool at their disposal – the practice of value engineering.</p><p>Get your free copy of <em>Engineering Value: Balancing Design with Cost-Effective Production</em> by simply entering your details below.</p><p><strong>Download your free copy of </strong><em><strong>Engineering Value: Balancing Design with Cost-Effective Production</strong></em><strong> to learn:</strong></p><ul><li>Where in the “product maturity curve” to introduce value engineering</li><li>6 key approaches to finding hidden value</li><li>Why it’s finally possible to achieve design-procurement balance</li><li>How you can immediately start applying value engineering</li></ul><p>And much more. Enter your details to get instant access.</p><p><strong>From the guide:</strong></p><p>“There’s good news here, though. You can adopt a practice dedicated to identifying hidden costs that can be eliminated to make manufacturing less expensive—without compromising performance.”</p><h2>Download your copy to learn more.</h2>

Discover how value engineering in die casting helps design engineers reduce costs without compromising part integrity.

Balancing Design with Cost-Effective Production | Dynacast

Download "Engineering Value: Balancing Design with Cost-Effective Production" to learn how value engineering can reduce manufacturing costs without sacrificing design integrity.

Engineering Value

<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 <strong>thixomolding</strong>.</p><h2><strong>MgCarbonit91: A High-Strength, Fire-Retardant Magnesium Alloy</strong></h2><p>Traditionally, the challenge with magnesium alloys 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?

<p>Injection metal assembly (IMA) is a 4 step process that replaces and outperforms conventional methods of assembly including crimping, soldering, staking, and welding. IMA is well-suited for assembling components of different shapes, sizes, and materials, including metals, ceramics, glass, fibers, paper, elastomers, and plastics.</p>

Injection metal assembly (IMA) is a 4 step process that replaces and outperforms conventional methods of assembly including crimping, soldering, staking, and welding. IMA is well-suited for assembling components of different shapes, sizes, and materials, including metals, ceramics, glass, fibers, paper, elastomers, and plastics.

What Is Injected Metal Assembly?

Experience precision and efficiency with our multi-slide zinc machines featuring fully-automated in-line processing, centergate technology for flash-free components, in-line gate separation, and automated runner system return, ensuring ultimate precision, part-to-part repeatability, and a seamless "packing ready" process at our die cast cell - discover the future of metal injection molding with our 35 machines strong lineup.

Multi-Slide Zinc Die Casting Process

<p>Dynacast is able to create custom precision components with tolerances of +/-0.02mm. With our multi-slide process, we can create net shape parts typically without secondary operations—including internal and external threads. The end result is a high-speed, temperature-controlled process that produces thin-walled components so complex in geometry that they would need to be manufactured from two or more pieces if other methods of die casting were used. If you require small complex components, multi-slide die casting may be your best solution. Contact our engineering team to get started on your project.</p>

Dynacast is able to create custom precision components with tolerances of +/-0.02mm. With our multi-slide process, we can create net shape parts typically without secondary operations—including internal and external threads. The end result is a high-speed, temperature-controlled process that produces thin-walled components so complex in geometry that they would need to be manufactured from two or more pieces if other methods of die casting were used. If you require small complex components, multi-slide die casting may be your best solution. Contact our engineering team to get started on your project.

Multi-Slide Die Casting Process

Dynacast offers proprietary multi-slide, hot chamber aluminum die casting. This high-speed process has production capabilities of up to 10 cycles per minute, while ensuring uniformity across parts.

Multi-Slide Aluminum Die Casting

Injected metal assembly (IMA), a form of insert molding, is a manufacturing process that uses a molten zinc alloy to join two or more components together to create a single, assembled part. The process is similar to injection molding, but instead of using plastic, it uses zinc. The IMA process starts with the creation of a custom tool that has the cavities for the two or more components and the injection ports. The components are then placed in the tool and the molten zinc is injected. The zinc alloy flows into the cavities and hardens to create a permanent bond between the components.

Injected metal assembly (IMA), a form of insert molding, is a manufacturing process that uses a molten zinc alloy to join two or more components together to create a single, assembled part. The process is similar to injection molding, but instead of using plastic, it uses zinc. 

The IMA process starts with the creation of a custom tool that has the cavities for the two or more components and the injection ports. The components are then placed in the tool and the molten zinc is injected. The zinc alloy flows into the cavities and hardens to create a permanent bond between the components. 

Injected Metal Assembly (IMA) Process

Dynacast Peterborough is known for its multi-slide technology, standard die casting with integrated automation, and IMA (Injected Metal Assembly) precision zinc manufacturing. The Peterborough facility is dedicated to designing, building, manufacturing, and delivering quality die cast components. 

Dynacast Peterborough Facility Spotlight

<p>Dynacast Lake Forest facility is dedicated to die casting zinc alloys with both conventional and multi-slide machines, as well as die casting aluminum alloys. Dynacast Lake Forest is equipped with state-of-the-art technology to provide the highest quality die casting parts. </p>

Dynacast Lake Forest facility is dedicated to die casting zinc alloys with both conventional and multi-slide machines, as well as die casting aluminum alloys. Dynacast Lake Forest is equipped with state-of-the-art technology to provide the highest quality die casting parts. 

Dynacast Lake Forest Facility Spotlight

<p>Take a journey through the Dynacast Peterborough tool room. In-house die cast tool design offers companies greater flexibility, control, customization, and responsiveness. It streamlines the production process, improves collaboration between design and production teams, and contributes to long-term cost savings and product quality enhancement. </p>

Take a journey through the Dynacast Peterborough tool room. In-house die cast tool design offers companies greater flexibility, control, customization, and responsiveness. It streamlines the production process, improves collaboration between design and production teams, and contributes to long-term cost savings and product quality enhancement. 

Die Cast Tooling & Engineering Capabilities

<p>From material selection to choosing the optimal process and eliminating secondary operations, Dynacast’s engineers work with each customer during the design process to make sure the part design will succeed in mass production. One of the major differentiators that distinguish Dynacast from other die casting companies is the quality of our tooling. All of our dies are made using a specific steel type with an additional heat treatment that can withstand a high number of shots and maintain the integrity of the component being manufactured. With little downtime, our tools create consistent, complex parts shot after shot and last longer than most of our competitors. Our multi-slide tools often come with a lifetime warranty.</p>

From material selection to choosing the optimal process and eliminating secondary operations, Dynacast’s engineers work with each customer during the design process to make sure the part design will succeed in mass production. One of the major differentiators that distinguish Dynacast from other die casting companies is the quality of our tooling. All of our dies are made using a specific steel type with an additional heat treatment that can withstand a high number of shots and maintain the integrity of the component being manufactured. With little downtime, our tools create consistent, complex parts shot after shot and last longer than most of our competitors. Our multi-slide tools often come with a lifetime warranty.

Benefits of Dynacast Tooling & Engineering Expertise

In this video, discover the fully-automated conventional zinc die cast cell with in-line robotic trimming. Conventional die cast tooling is designed with single or multiple cavities. The tool is designed to be efficient and cut down on secondary operations which help lower costs. Other benefits of conventional die cast tooling, include:<p></p><ul><li>Dies that are designed to efficiently manage high volume production</li><li>Net shape die casting, with design focused to avoid secondary operations</li><li>Steel braced dies to aid in the longevity of the tool</li><li>Efficient production with properly planned cooling and water lines</li></ul>

In this video, discover the fully-automated conventional zinc die cast cell with in-line robotic trimming. 

Conventional die cast tooling is designed with single or multiple cavities. The tool is designed to be efficient and cut down on secondary operations which help lower costs. Other benefits of conventional die cast tooling, include: 

Dies that are designed to efficiently manage high volume production 
Net shape die casting, with design focused to avoid secondary operations 
Steel braced dies to aid in the longevity of the tool 
Efficient production with properly planned cooling and water lines 

Conventional Zinc Die Casting Process

Aluminum die castings are lightweight and able to withstand the highest operating temperatures of all die cast alloys. One of the most significant benefits of aluminum die casting is that it creates lighter parts—with more surface finishing options than other die cast alloys. Aluminum can also withstand the highest operating temperatures of all the die cast alloys. Moreover, cast aluminum is versatile, corrosion resistant; it retains high dimensional stability with thin walls and can be used in almost any industry.

Aluminum die castings are lightweight and able to withstand the highest operating temperatures of all die cast alloys. One of the most significant benefits of aluminum die casting is that it creates lighter parts—with more surface finishing options than other die cast alloys. Aluminum can also withstand the highest operating temperatures of all the die cast alloys. 

Moreover, cast aluminum is versatile, corrosion resistant; it retains high dimensional stability with thin walls and can be used in almost any industry. 

Conventional Aluminum Die Casting

<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 Dynacast 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 zinc die casting and surface finishes. “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

<h2>Moving from Plastic to Metal for Ultimate Part Strength</h2><p>Dynacast was presented with manufacturing an electrical motor pinion. The pinion is an integral part in the overall function of the motor, requiring precise tolerances and high strength material.</p><h3>Plastic versus metal components</h3><p>Initially, the customer designed the part in plastic, but once the part was put into testing, heat and distress requirements caused the part to fail. Additionally, the plastic production process failed to meet technical requirements needed for part performance. The customer required tighter tolerances and complex component design for the electro-mechanical mechanism to achieve optimal performance, so they turned to Dynacast for a solution.</p><p></p><img asset_uid="bltb31a0308361cb55d" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/bltb31a0308361cb55d/670690310d6784b9be23e708/Picture15.jpg" alt="Picture15.jpg" height="auto"/><h3>Prototyping and metal solutions</h3><p>With material strength being the customer’s main priority, Dynacast utilized a prototype tool to test various alloys, allowing design engineers the ability to quickly and efficiently test for performance, and craft even better components.</p><p>The first prototypes were made using Zamak 5. Zinc alloy 5 is the most widely used zinc alloy in Europe and is known for its hardness and high-strength properties. But despite an improvement from plastic, the resistance was not enough. Zamak 2 was tested next, due to a higher resistance and higher hardness, however, the design engineers knew there was another option.</p><p><strong>EZAC®</strong>. This hot chamber zinc alloy has superior creep resistance, high yield strength, high hardness, and low melting temperatures. While zinc has always been known for its high strength, the addition of EZAC® to the list of alloys Dynacast can cast makes this zinc alloy more suitable for applications like this pinion that require high surface hardness.</p><p>The customer put Dynacast’s EZAC castings under severe endurance testing and were extremely pleased with the new material, making it an easy choice to switch from plastic injection molding to die casting.</p><p>If you are looking for a partnership to help you apply new tools and technologies, or help you fully realize your design vision, let us help you move your business forward, contact our team today to get the conversation started.</p>

Learn how moving from plastic to metal die casting boosts part strength, durability, and performance.

Move from Plastic to Metal for Ultimate Part Strength

Dynacast helped a customer improve the strength and performance of an electrical motor pinion by transitioning from plastic to a high-strength EZAC® zinc alloy, ensuring tighter tolerances and better endurance under extreme conditions.

Moving from Plastic to Metal for Ultimate Part Strength

<h3>Machining Conversion to Die Casting</h3><p>If you’ve seen the breathtaking aerial footage drone cameras are capable of, you know it’s possible to get film-like, smooth video from today’s go-anywhere cameras. GoPro needed to affordably deliver that same, incredible stability to adventure athletes on the ground, underwater, or in flight—instead of the bounced-around “shaky cam” look that’s inevitable with a handheld device.</p><h3>Bringing Video Down to Earth</h3><p>Without stabilization, the jarring agitation of any handheld video is obvious on screen.</p><p>It’s even worse for adventure athletes: the conditions are anywhere from unpredictable to extreme; there’s not always a logical place to mount the camera; and “just stand still” is a foreign concept. For these video creators, stabilizing equipment is key.</p><p>GoPro already had a stabilization system for use with a quadcopter-style drone, but customers love to get close-up footage right inside the action.</p><p>The company decided to re-purpose the drone mounting component into a piece customers could use to attach GoPro cameras to handheld and body-worn stabilizers instead.</p><h3>Epic Versatility</h3><p>“The products we make endure a wide variety of uses,” explains Matt Thomas, Mechanical Engineering Manager for GoPro accessories. “Everything from skiing to SCUBA diving to chasing your kids through a park.”</p><p>That meant the mount would have to be strong—and for consumer use, it would need to provide cost savings through thousands of units and many years. In order to expedite time to market, GoPro’s designers initially specified the mount as an all-machined metal component.</p><p>“While that was the quickest way for us to get to market,” says Thomas, “it was also more expensive. So in parallel, we investigated a longer term, more cost-friendly option.”</p><p><strong>To determine the optimal materials and processes to reduce costs for the replacement part GoPro wanted, the team brought in Dynacast.</strong></p><h3>Casting Decisions</h3><p>“We utilized Dynacast’s services in the past on a number of projects, and they’ve become one of our top tier suppliers,” says Thomas. The two companies had also worked together in sessions that Dynacast held to explore cost reduction and manufacturability improvements. And the first thing they agreed on was minimizing the costs related to processing.</p><p>“Extrusion is great for making a two-dimensional part, but then when you add other features to it, you have to machine it as a secondary process, and that’s what adds the cost,” says Bill Heilman of Dynacast. “We told them, you don’t have to add machining. We can just cast it in that shape.”</p><h3>Handle—With Care</h3><p>The GoPro team’s overarching goal was to reduce the cost but had other requirements for the part too. “We needed strength and a lightweight component. Something that would handle a variety of environmental situations,” says Thomas.</p><p>And, since the part is a handle that people would operate with their fingers (often in extreme conditions, and maybe not with the gentlest touch), the team needed to make sure that the feel would be acceptable to the end user.</p><p>Because materials have different options for surface treatments, keeping the post processing work to a minimum was important, with respect to secondary polishing and machining of the components—and getting the precise anodization color. They ultimately cast it in aluminum, to match the existing parts on the mount—but also to achieve their cost-reduction goals.</p><h3>Material Selection</h3><p>“We tell customers, ‘Don’t assume because you chose one particular manufacturing process that that’s the only way to make the part,’” says Dynacast’s Heilman.</p><p>Matt Thomas would agree. “When we first started, the cast part represented an approximately 50% savings over the machined part”—making die cast aluminum a clear choice for both cost reduction and manufacturability goals.</p><p>“It’s great to see product out on the market and being sold,” says Thomas. “Dynacast is very responsive, very timely with their communication, easy to work with. It’s just the ease of collaboration in taking the design from concept to tooling.”</p><p>If you are looking for a partnership to help you apply new tools and technologies, or help you fully realize your design vision, let us help you move your business forward, contact our team today to get the conversation started.</p>

Discover how converting from machining to die casting lowers costs, improves speed, and boosts precision.

Switch from Machining to Die Casting for Efficiency

This case study highlights how GoPro partnered with Dynacast to convert a machined metal component into a die-cast aluminum part, resulting in significant cost savings and improved manufacturability for their camera stabilization mounts.

Machining Conversion to Die Casting

<h3>Improved Die Cast Supply Chain</h3><p>When a part used in thousands of Honda SUVs became challenging to deliver, Piolax USA inspected its entire supply chain to find the root of the problem.</p><p>All signs indicated the die cast part itself was the issue, one Piolax might have to live with—until other suppliers got the manufacturer hooked on Dynacast.</p><p>Piolax USA makes a product range of metal and plastic automotive parts that span the entire vehicle, from clamps and harnesses to powertrain and fuel parts.</p><p>“We’re 100% automotive,” says Josh Miller, Purchasing Manager at Piolax USA.</p><p>That’s no overstatement. Its Japanese-owned parent company, Piolax Incorporated, is a giant in the industry. Currently, in its 85th year in business, it’s traded on the Tokyo Stock Exchange and serves an impressively demanding client list.</p><p>“Nissan is our majority customer, and we’re tier one to Ford, Honda, Toyota, and GM,” Miller says. The relationships extend to many of those brands’ other suppliers, too.</p><p></p><img asset_uid="bltaa91a19e5c69895c" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/bltaa91a19e5c69895c/67068dc902bc600d1edae260/Picture13.jpg" alt="Picture13.jpg" height="auto"/><p>With a global industry counting on them for parts, Piolax—which stands for ‘pioneers of elasticity’—needs a supply chain as adaptable as its name.</p><h4>Supply Chain Audit</h4><p>A decade ago, the Canton, Georgia-based manufacturer started a project with Honda. “The application was a tie down assembly,” Miller says. “It allows people to tie down luggage or anything they want securely anchored in the SUV cargo bed.”</p><p>For years, the project had continued along routinely, and Piolax received product only after it was cast, sanded, buffed, and plated. But over time, the part was added onto different platforms, models, and other configurations, leading to higher volumes—and struggles with on-time delivery.</p><p>To determine the root of the problem, Piolax toured every supplier involved in the part.</p><p>“We found that most of our suppliers—the plater, the buffer, and the sander—were world class,” says Miller. “The actual manufacturing, the casting of the hook, was the weak point.”</p><h4>Stretched for Time and Quality</h4><p>Initially, Piolax had used a die caster in neighboring Alabama to produce the part. But as the project grew, the supplier became a bottleneck—especially with the levels of quality and cosmetics the part required.</p><p>“With chrome-plated die cast parts, everything has to come together precisely,” says Brad Doornbos of Dynacast. “Tooling, tool temperature, fill rate—every condition has to be just right.”</p><p>When it’s not? “If that part comes out of the tool with any imperfection,” Doornbos says, “the chrome plating will accentuate and magnify even the tiniest defect on the surface.”</p><p>That means adding delays, costs, and waste, either through sanding and buffing further along in the process or scrapping the cast parts outright before they’re even shipped. Either way, Piolax had found their problem.</p><h4>Confidence and Capability</h4><p>For the newest version of the part, Miller and his colleagues tapped their other suppliers for advice. They asked: “Who do you recommend that without a doubt can produce a very high-quality part that will be visible to the end customer?”</p><p>“The first company they suggested was Dynacast,” Miller says.</p><p>He added Dynacast’s Peterborough, Ontario plant to his audit. That visit, he says, validated his suppliers’ conviction that Dynacast could deliver parts to Piolax standards.</p><p>“You could tell they were experienced in similar projects. The appearance issue we had with the previous part was not intimidating to them; it was well within their capability,” says Miller.</p><p>His meeting with Dynacast’s engineering experts reinforced his impressions. After that visit, Piolax awarded the new project to Dynacast—but that wasn’t all.</p><p>“From the professionalism, the organization, and the exactitude they displayed, it was obvious they knew exactly what they were doing,” Miller says. So, in addition to the new project, he canceled his previous project with the other die caster—and enlisted Dynacast to take it over.</p><p>“On-time delivery, quality, communication, and price had been difficult with our old supplier,” says Miller. “The thing is, those are the four key areas that have to be strong for us—and for our customers. And those were the things I knew Dynacast would deliver.”</p><p><strong>"I knew Dynacast would be a solid supplier to Piolax. Not only now, but somebody we could partner with, move forward with, and grow with in the future." - Josh Miller, Piolax</strong></p>

Improve supply chain stability and reduce risk with reliable die casting processes and strategies.

Strengthen Your Supply Chain with Die Cast Solutions

A manufacturer improved its die cast supply chain for a critical part by partnering with Dynacast, which resolved quality and delivery issues previously experienced with another supplier.

Improved Die Cast Supply Chain

<h2>From Plastic to Zinc Die Casting</h2><p>"We’re a really small startup. Dynacast made sure we could get to market on time." - Andrea Perdomo, Revolar</p><h3>A Magic Button</h3><p>In vulnerable situations, the difference between feeling powerless and being secure can come down to one question: how quickly could you signal someone for help if you needed it?</p><p>Most people carry smartphones with them outside the house. But using one to SOS in unexpected situations isn’t exactly instantaneous.</p><p>Fumbling with a dial pad, calling an emergency number, and explaining the potential threat can add many adrenaline-filled moments—not to mention confusion about the person’s precise location.</p><p>This complexity is what led Revolar cofounders Jacqueline Ros and Andrea Perdomo—both of whom have close relatives who survived traumatic personal danger—to come to a shared epiphany.</p><p>“If only they’d had a ‘magic button’ they could have pressed to let us know they needed help, they would have been able to avoid so much,” says Perdomo.</p><p>And the Revolar safety device was born. Clipped onto keychains, backpacks or purses, one click sends an “all clear” check-in to chosen contacts, while additional clicks escalate the urgency, so contacts can help—or send first responders.</p><p>The pair bootstrapped their startup, funded it with a Kickstarter campaign, and landed outside funding, before getting coveted shelf space for their first-generation device in Brookstone, Target, Amazon, and BestBuy. But months of testing revealed that consumers wanted a second-generation product with a smaller, more premium form factor that would fit right into their lifestyle. Consumers wanted the button to feel less like a device and more like an accessory.</p><h3>Manufacturing Fashion</h3><p>To arrive at the ideal specs, Dynacast took Revolar through DFM (design for manufacturing) sessions covering process, material, and finishes.</p><p>“This next-generation device needed a stronger part,” says Dan Taylor of Dynacast. “It needed a feeling of higher quality, which a lot of our customers like—that heavier, metallic part in their hand—because it feels much stronger than plastic parts.”</p><p>Dynacast’s recommendation was zinc, which for die casting applications can be made thinner, more intricate, and more complex even at incredibly small sizes.</p><p></p><p></p><figure style="text-align: left"><div data-img-caption-container="true" style="display: inline-block; text-align: center;"><img alt="Picture1.jpg" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt3380e4080389a964/6706036e0d6784c13723e172/Picture1.jpg" height="auto" style="text-align: left;" /></div></figure><h3>Design Down to The Wire</h3><p>“We had a plating ‘recipe’ for the finish of this part, whether it was sandblasting it, bead blasting it, then adding different types of copper-nickel plating,” says Dynacast’s Taylor. But Revolar hadn’t yet confirmed the finish.</p><p>Then they visited Dynacast’s plant in Batam, Indonesia, where they looked at some automotive key fob parts that were about the same size as Revolar’s design. Says Taylor, “They liked the components, which were beautiful and small, and the finish, which was a very shiny, satin chrome. They said, ‘That’s what we want.’”</p><p>It took time for tooling to begin, precisely because the design was evolving so significantly through testing and trials. Andrea Perdomo says, “We asked Dynacast to do some expediting of tooling production, and other manufacturers might not have accommodated that. We’re a really small startup. Dynacast made sure we could get to market on time.”</p><p>In the end, the philosophy of design freedom embraced by Dynacast was a major advantage; not only to accommodate tight timelines, but also the flexibility of finishes that Revolar wanted, to make a device its customers would be pleased to make a habit of wearing.</p><p>“Our product is beautiful, it’s functional, and it’s affordable,” says Perdomo. “And it’s largely because of the Dynacast experience.”</p><p>If you are looking for a partnership to help you apply new tools and technologies, or help you fully realize your design vision, let us help you move your business forward, contact our team today to get the conversation started.</p>

Convert plastic parts to zinc die casting for enhanced strength, speed, and precision in manufacturing.

From Plastic to Zinc: Strength & Speed for Die Casting

Dynacast's collaboration with Revolar turned their vision for a sleek, high-quality safety device into reality, using zinc die casting to achieve the perfect balance of durability and aesthetic appeal

From Plastic to Zinc Die Casting

<h2>DOOR-IN-DOOR FEATURE FOR ENERGY-EFFICIENT REFRIGERATOR</h2><p>The average household refrigerator is opened 22 times per day. With each look inside, cold air escapes and warm air from the surrounding room circulates through. Once the doors are closed, the compressor must kick-in to re-cool the air and contents inside--impacting the owner’s energy bill and environmental footprint. But what if there was a way to access everyday items, such as drinks and snacks, without affecting the rest of the internal contents?</p><p></p><img asset_uid="bltd37d37ea0927e96f" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/bltd37d37ea0927e96f/670692c50d678426a923e75f/Picture17.png" alt="Picture17.png" height="auto"/><h2>INNOVATION THROUGH ALUMINUM DIE CASTING</h2><p>When the design team at a leading appliance manufacturer approached Dynacast to learn about die casting capabilities, they were unsure where and how they could benefit from the manufacturing process. The team at Dynacast Elgin was eager to help and offered an educational seminar to design engineers, outlining technical capabilities, material offerings, and overall benefits of die casting in the appliance industry. With a new design in mind, the engineers engaged Dynacast’s design for manufacturing (DFM) to find the best solution. Aluminum was very attractive to the team due to its lightweight properties and its high strength-to-weight ratio. Specifically, appliance engineers focused on decorative aluminum die casting for a new French-door refrigerator concept. The appliance would offer a door-in-door feature to allow the consumer access to popular items without opening the entire refrigerator and wasting cold air. By allowing the interior doors to stay closed and keep warm air out, the refrigerator would offer an innovative way to reduce energy consumption.</p><p></p><img asset_uid="blt871d3bf515f59c88" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt871d3bf515f59c88/670692c5a75c92f2970a2b62/Picture18.jpg" alt="Picture18.jpg" height="auto"/><h2>MAXIMIZING “SHELF LIFE”</h2><p>The appliance company’s marketing team was interested in offering a swinging “milk shelf” to allow easy access to the common household staple. Connection of the milk shelf to the interior body of the refrigerator would happen via a hinge component. In order to withstand the weight of a gallon of liquid, engineers determined the hinge would need to be stronger and more durable than plastic. The castability of zinc, its wear resistance, and structural integrity made it the ideal material choice.</p><p></p><img asset_uid="bltbcfda9c92a3fe4c1" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/bltbcfda9c92a3fe4c1/670692c5a75c9286890a2b64/Picture19.jpg" alt="Picture19.jpg" height="auto"/><p>In addition to offering functionality and stability, the shelf attachment needed to be decorative since it would be visible to consumers. Decorative aluminum die casting offered an eye-catching design and provided the rigidity and strength required. <strong>Dynacast Elgin designed and manufactured three parts in total: a decorative, aluminum die casted shelf and two, multi-slide zinc hinge components.</strong></p><h2>DYNACAST DELIVERS</h2><p>Dynacast strives to ensure every customer receives insight and expertise that adds value at every stage of the design and die cast manufacturing process. It’s why today, across multiple industries and multiple geographies, Dynacast is the name synonymous with precision-engineered metal components. <strong>Their extensive knowledge of metal die casting and reliable reputation made them a valuable partner for the appliance manufacturer.</strong></p>

Discover how aluminum die casting enhances energy efficiency while maintaining strength and performance.

Improve Energy Efficiency with Aluminum Die Casting

Dynacast helped a leading appliance manufacturer enhance energy efficiency in a new refrigerator design by utilizing aluminum die casting for a door-in-door feature, reducing cold air loss and lowering energy consumption.

Energy Efficiency Through Aluminum Die Casting

<h2>Eliminating Automotive Part Failure through DFM</h2><p>Many auto manufacturers have addressed the needs of their customers by installing locking fuel doors. As a frequently used component on a vehicle, it is critical that the lock itself doesn't fail so the driver can access the fuel tank and adds a level of security for the driver.</p><h3>Low-grade tooling and metal injection inconsistencies</h3><p>The fuel door lock manufacturer originally designed the part using aluminum. And once the design entered the first production run at the original foundry, they ran into inconsistent material shrinkage within the conventional tool. There were also problems filling the part—leaving inconsistencies from part-to-part and component failure. Due to poor material choices, as well as the lack of quality engineering, the part was destined to fail and lead the customer to seek out another solution.</p><p><strong>That’s where Dynacast comes in.</strong></p><p><strong></strong></p><img asset_uid="bltb893e56bb63e754e" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/bltb893e56bb63e754e/67067e174c601d11ff5186f3/Picture3.jpg" alt="Picture3.jpg" height="auto"/><h3>Die Casting vs. Machining</h3><p>It was clear that not only did the design need updating, but the process needed to be analyzed, as well. After reviewing different metalworking processes, the customer narrowed the decision down to machining and die casting. Although precision metal components are achievable through both production processes, the choice often comes down to efficiency and cost.</p><p>Dynacast’s multi-slide machines can be designed with multiple cavities and enable our engineers to cast extremely complex parts, quickly. A faster cycle time contributes to lowered overall cost per piece. Additionally, die cast tools ensure unmatched complexity of internal and external geometries, so there are fewer secondary operations associated with die casting. With the customer deciding on die casting, we were able to get started.</p><h3>Engineering expertise, software integration, and quality tooling</h3><p>The first step to eliminating the possibility for part failure was to find an engineering team that provides design for manufacturing (DFM) insight on the front end of the project. Dynacast engineers analyzed the design and used software to simulate the casting process, identify gating locations, and optimize the die for quality and longevity. And through the DFM process, our team of engineers identified Zamak 5, or zinc alloy 5, as the optimal casting metal. High strength and exceptional hardness made zinc the ideal alternative to aluminum.</p><p></p><img asset_uid="blt076f2e9917987f20" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt076f2e9917987f20/67067e1664332c657f8ebc3d/Picture4.jpg" alt="Picture4.jpg" height="auto"/><p>Dynacast engineering experts continued to uncover problems surrounding part failure. The original design presented poor material flow which directly affected the structural integrity of a part. With a well-planned tool design and a carefully controlled process, you can minimize part inconsistencies and achieve higher quality components. In this case, the Dynacast technical team was able to find the perfect gating solution for the part, as well as identify a 2-cavity tooling solution with an insert and interchangeable pins.</p><p>The quality tooling Dynacast was able to provide allowed for a much longer tool life that positively impacted the productivity level of the locking fuel door part. And with the large volumes, the customer needed a tool that would hold up over time and create quality components consistently. The multi-slide zinc tooling solution that Dynacast engineers provided the customer allowed for much more control and stability during production.</p><p></p><img asset_uid="blt9d2896fe3e0305c1" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt9d2896fe3e0305c1/67067e166c7a35754be3f3b9/Picture5.jpg" alt="Picture5.jpg" height="auto"/><h3>Satisfied customer</h3><p>Dynacast was able to provide the customer with the overall best solution. The ability to produce high-strength, precision components with quality tools, all while providing lower part prices in a timely manner, allowed Dynacast to secure the project and deliver valued parts.</p>

See how DFM strategies help eliminate part failure risks and improve reliability in automotive casting.

Prevent Automotive Part Failure with DFM

In design for manufacturing (DFM) and advanced die casting technology resolved automotive fuel door lock failures by replacing suboptimal aluminum with high-strength zinc alloy, optimizing tooling and production processes for enhanced quality, durability, and cost efficiency.

Eliminating Automotive Part Failure through DFM

<h3>Design For Manufacturing Success</h3><p>Musculoskeletal disorders on the job cost employers $50 billion annually. But there are some jobs—even entire industries—in which machines just can’t perform as well as a highly trained, real-life person. Levitate Technologies set out to create a solution for professionals whose work requires constant shoulder mobility. In the process, and with the help of Dynacast, they ushered in the new age of worker safety and productivity: exoskeleton technology.</p><h4>Repeat Performance</h4><p>From automotive plants to manufacturing lines, millions of professionals work with their arms elevated, in a static position, or performing a repetitive motion for long periods of time.</p><p>To reduce fatigue and injury, companies provide ergonomic solutions like braces and stands; but until recently there has been no truly supportive solution for the shoulder joint. The consequences: skilled professionals who injure themselves or age out of a career too soon.</p><h4>Providing a Helping Hand</h4><p>“It’s a problem out there, and it’s a very costly problem,” says Joseph Zawaideh, VP of Marketing &amp; Business Development at Levitate Technologies. “Anything you can do to relieve fatigue, to reduce injury, to make workers happier is a welcome solution that manufacturers are very interested in exploring.”</p><p>It was that goal of reducing worker fatigue, physical burnout, and injury, while not intruding on the workspace that drove Levitate founder, President &amp; CEO, Mark Doyle to develop the innovative designs for what would become the AirframeTM. The Levitate team worked with the new production introduction team at Pathway NPI in San Diego, CA, to engineer and manufacture the technology.</p><h3>A Welcome Relief</h3><p>In his vision, a sleek, lightweight upper body exoskeleton could transfer part of the weight of the arm off of the wearer’s shoulder, neck, and upper back and disperse it safely to the core body—greatly reducing the risk of injury and muscle weakness.</p><p>To accomplish this and keep the wearer’s workspace clear of obstructions, the exoskeleton would need to utilize the most precise ergonomic technology, and be made as light and convenient to wear as possible.</p><p>Importantly, the AirframeTM would have to be manufacturable in quantities that companies around the globe could procure to protect and enable their employees. This critical factor narrowed the field of outsource manufacturers that Levitate could engage, and Mark went to great lengths to find the right one to choose for a partner.</p><p>“They had to be the best of the best,” says Mark, “because we’re going to be making tens of thousands of these devices. Workers around the world are going to be applying pressure on them all day long. Only a company like Dynacast can really provide that level of precision with that level of load management.”</p><h3>Design for Manufacturability</h3><p>Dynacast’s engineers helped ensure the quality, rigidity, and performance of Levitate’s new exoskeleton technology through a series of comprehensive design for manufacturability (DFM) sessions over several months.</p><p>“Before Dynacast, Levitate had not done any of the design for manufacturability work. In fact, all of DFM was driven by Dynacast,” says Mark.</p><p>This was crucial, specifically because the shoulders of the Airframe™ include cassettes filled with tiny components that essentially drive the device and disperse the weight to the core body.</p><p>“The components have to be very rigid and withstand the load, but they also have to be ultralight at the same time. It’s almost like a surgical instrument level of accuracy, but body worn,” says Joseph.</p><p>Dynacast’s engineers solved tricky tolerance, width, and size issues and ultimately specified die cast processes, both for the zinc parts—making them exceedingly durable—and for aluminum, making it incredibly lightweight.</p><h3>Removing the Burden</h3><p>“The final prototype that Dynacast helped us build is in the hands of real users wearing it in real plants,” says Joseph. And the feedback from global companies working with those prototypes? “’We want to order more.’”</p><p>Exoskeleton technology is on the rise as more companies realize its potential as a solution to worker safety, opening Levitate up to new competition. But, thanks to its patented designs and Dynacast’s commitment to its development, it can be manufactured three times lighter than any other exoskeleton currently in production.</p><p>“We engineer solutions. We always want to get involved very early-on with a program so we can engineer the best components and be part of the solution.” – Dan Taylor, Dynacast</p>

Learn how design for manufacturing (DFM) principles improve part quality, efficiency, and cost control.

Design for Manufacturing: How to Ensure Success

Design for Manufacturing Success

<h2>Converting Plastic to Zinc for Speed and Tight Tolerances</h2><p>Window blinds have recently benefited from engineering innovations that are driving an interior design revolution. Springs Window Fashions is leading the charge, with blinds that do more than just look good: they manage light and temperature, conserve energy, and help enterprises support their brands visually. So when the company sought a partner to help design and produce critical components using zinc instead of plastic, it needed a trusted specialist to deliver the anticipated production and commercial gains. Dynacast took up the challenge.</p><p></p><img asset_uid="blt7a45c6c4485db4d9" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt7a45c6c4485db4d9/670691526c7d6c698a656149/Picture16.jpg" alt="Picture16.jpg" height="auto"/><h4>A passion for window fashion</h4><p>North America’s home décor industry is huge. The growth of Wisconsin based Springs Window Fashions reflects the scale of this opportunity, employing 5,000 people across its nine production facilities.</p><p>Window blinds can add unique style to homes and businesses. Increasingly though, they add more to environments than visual interest. They also feature motorized and automated controls, frequently integrating with other room management systems such as air conditioning.</p><p>We interviewed Michael Graybar, a product engineer at Springs Window Fashions, to learn more about how the product design process drives success – and how Dynacast efficiently delivered critical new zinc components.</p><h4>In-house product design</h4><p>Springs Window Fashions has a full engineering lab and undertakes much of its product design in-house. As a business, it has also become adept at plastic injection molding, a process at the heart of its products and manufacturing methods. “We work very fast,” said Michael Graybar. “The product development process is getting shorter and shorter.”</p><h4>Engineering advances</h4><p>“Engineering changes all the time, and processes change with it,” he added. So when a requirement arose for a system-critical, heavy load carrier component, Graybar decided he needed to look beyond plastic.</p><p>Springs Window Fashions favored zinc because of its strength, resistance to material creep, low cost, and suitability for die casting. Dynacast was among the first suppliers Graybar approached, as he had worked with the company on previous projects, and knew it offered specialized die casting capabilities.</p><p>Graybar stated, “We’ve had issues in the past with the porosity of zinc products sourced from overseas, but we felt that Dynacast offered the reliability and expertise we needed.”</p><h4>Partners in design</h4><p>“Speed, cost effectiveness, the ability to meet very tight tolerances, and materials expertise all helped make Dynacast a valuable partner for Springs Window Fashions.</p><p>Undercut feet were a unique feature of the new planetary output carrier and shaft design, aiding manufacturing efficiency and countering the thrust load from the helical gear teeth.</p><p>During the project, Graybar liaised with a Dynacast specialist with direct access to the tooling team, saving time and ensuring any issues were rapidly resolved. Developing products and taking them to market quickly is key to success in the window treatments business, and Dynacast was able to supply the components employing its six-slide mold, further reducing tooling time and costs.</p><h4>Material differences</h4><p>Dynacast took part in web conferences with Graybar’s team, discussing the pros and cons of different production methods, resolving engineering issues, and then executing the agreed approach.</p><p>“They were really good,” said Graybar. “Dynacast provided solutions and were very knowledgeable on zinc product properties, as well as coatings.” Dynacast’s experience and expertise allowed them to advise on issues of stability and dimensional tolerances.</p><h4>Clear advantage</h4><p>The partnership between Springs Window Fashions and Dynacast resulted in a rapid development process, lower costs, and – most importantly – a durable, high-quality end product. This translated into clear competitive advantages in the home décor retail market.</p><p>Michael Graybar summed up, “The planetary output carrier and shaft came in perfect first time. My contact at Dynacast was so responsive – he really wanted us to have quality parts. I’ve been very impressed with what they do.”</p>

Discover how converting plastic parts to zinc die casting delivers speed, strength, and tight tolerances.

Convert Plastic to Zinc for Faster Precision

Dynacast partnered with Springs Window Fashions to convert a critical component from plastic to zinc, delivering faster production, tighter tolerances, and a more durable product that provided a competitive edge in the home décor market.

Converting Plastic to Zinc for Speed and Tight Tolerances

<h3>CNC Machining to Cost-Effective Die Casting</h3><p>Realizing most people were turning to their cell phones for always-on photography, Light set out to develop a new type of camera. One that combined the convenience and portability of a cell phone with the high image quality of a DSLR rig.</p><p>To make this groundbreaking and highly precise technology perfect, they knew there was only one manufacturing process that could meet their extraordinarily tight spec—and that only Dynacast could build it.</p><h4>Today, everyone is a photographer</h4><p>You see it everywhere: people of all levels of skill and enthusiasm, snapping images with their smartphones at the instant something interesting happens, and then publishing them to the world within the moment.</p><p>But those images aren’t the best quality, given the optics and the processing limitations of our smartphones—consumer devices that are pressed into service for so many tasks that photographic imaging is not a priority for manufacturers.</p><p>On the other hand, having an easy-to-use camera always ready gives the smartphone size and shape a distinct advantage. DSLR cameras are cumbersome and difficult to have at the ready for that impromptu moment of photo magic.</p><h4>Convenience meets quality</h4><p>The innovators at Light saw that smartphones were just not good enough for people who want to capture emotional, never-to-be-duplicated life moments with the professional quality that a DSLR could.</p><p>Their invention, the Light L16 Camera, employs 16 internal camera modules of multiple focal lengths simultaneously—letting in maximum light—then sews the images together computationally for a high-quality finished photo with nearly infinite depth-of-field control. All in a chassis the size of a cell phone.</p><p>So that chassis had to be perfect.</p><h4>Shedding light on the challenge</h4><p>Setting out, Light knew they needed the chassis to be kept as small as possible, and required a cost-effective option for a go-to-market product.</p><p>As work began, it became clear just how difficult it was going to be to build the product with such small dimensions, given the varying sizes of the internal components.</p><p>One very simple, but cost-prohibitive, alternative kept coming up—CNC machining. The problem? CNC machining the part costs five times more than die casting. Calling on past experience with Dynacast, Jennifer Hochstatter, VP of Operations at Light, knew they could help.</p><p>“Let there be no mistake: it was very challenging on Dynacast’s side to make this happen. We were demanding of die casting. They were up for the challenge, taking a risk on a small, unproven company, and they made it work,” says Jennifer.</p><h4>Seeing the process through</h4><p>The biggest hurdle during this project was creating the die cast part—at the size required—so that it could be duplicated on a scale of mass production.</p><p>That’s where Dynacast’s expertise came in—handling very tight tolerances and making very thin and small wall sections that are manufacturable on a large scale.</p><p>“This camera is really pushing the boundaries of what die casting is capable of. That’s why we required Dynacast’s help, in being able to accept those incredibly tight tolerances and really demanding specifications,” says Jennifer.</p><p>Secondly, with the incredibly complicated internal optics—mirrors bouncing light into sensors in tightly calibrated conditions—it was vital that the technique Dynacast used to finish the interior surface allowed for no reflection whatsoever. Likewise, the external surface required cosmetic painting to create an attractive consumer look rather than an industrial-looking fabrication.</p><p>“That processing also isn’t easy to get just right,” according to Jennifer. “That’s something else Dynacast could do, their ability to paint on an anodization. The type of aluminum material we’re using is very unique, and they’re one of the only ones in the world that can do it.”</p><h3>Investing in innovation</h3><p>“Having Dynacast be a part of this project, they’ve proven themselves to be a true partner, willing to buy into the dream that this camera is going to be a game-changing innovation,” says Jennifer.</p><p>Thanks to their strong commitment to collaboration, Dynacast was able to develop the ideal solution. Light has made their multi-aperture computational camera a reality, without having to compromise on camera size, manufacturing cost, or overall aesthetic design.</p><p>If you are looking for a partnership to help you apply new tools and technologies, or help you fully realize your design vision, let us help you move your business forward, contact our team today to get the conversation started.</p>

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See how switching from CNC machining to die casting can reduce costs and improve production efficiency.

From CNC Machining to Cost-Effective Die Casting

CNC Machining to Cost-Effective Die Casting

<h1>Get your free copy of “Which metal is right for me?”</h1><p>A visual metal reference guide. All in one place.</p><p>Your at-a-glance guide to key metals and their properties for die casting.</p><p>Get your free copy of “Which metal is right for me?” by simply entering your details below.</p><p>Download your free copy of “<strong>Which metal is right for me?”</strong> to learn about: </p><ul><li>The ideal applications for our most popular manufacturing materials</li><li>The key characteristics for specifying your project</li><li>Which manufacturing process a metal is suited for</li><li>More than a dozen alloys, and why you would specify them</li></ul><p>And it’s all in a simple, at-a-glance guide. Enter your details to get instant access.</p><p>From the guide:</p><p><em>“The ‘castability’ of zinc, its wear resistance, and structural integrity make it perfect for the creation of the multi-faceted, highly complex shapes used in the automotive safety and electronics industry.”</em></p><h2>Download your copy to learn more.</h2><p></p>

Compare die casting metals and discover the best option for your product's strength and performance.

Which Metal is Right for Your Die Casting Project?

Explore key metal properties, ideal applications, and alloy options for die casting—all in one convenient, at-a-glance reference. 

Which Metal Is Right For Me?

<h1>Get your free copy of Creativity Without Compromise</h1><p>Pressure die casting with zinc-based alloys is one of the most efficient and versatile high-production methods used for the manufacturing of strong, accurate, complex, and intricately shaped metal components. </p><p>The process is carried out in an automatic machine suitable to withstand high pressure. The molten metal is pushed by a hydraulically actuated plunger into a two-piece steel die containing one or more cavities, each an exact inverse replica of the part or parts being produced. Because of the quick chill and rapid solidification that takes place when molten metal comes in contact with the relatively cool steel side, and because the fine metallurgical grain structure that results, the mechanical properties of pressure die castings are generally superior to castings produced by other methods. </p><p>Zinc pressure die castings, for example, are stronger than sand cast 356-T6 aluminum, SAE 40 bronze, and class 30 cast iron. Also, pressure die cast components produced using the ZA alloys are stronger than pressure die cast aluminum 380 alloy. </p><h3>Please fill out the form to access your copy of the white paper.</h3>

Understand the high-pressure zinc die casting process and material options for strong, complex parts.

High-Pressure Zinc Die Casting Process Explained

This white paper explores the high-pressure zinc die casting process, highlighting its efficiency in producing strong, precise, and complex metal components compared to other casting methods. 

The High-Pressure Zinc Die Casting Process: Materials

<h1>Multi-Slide Hot Chamber Aluminum Machine</h1><p>Your biggest component production costs shouldn’t go to waste.</p><p>Download your free copy of our <strong>Multi-Slide Hot Chamber Aluminum Machine</strong> whitepaper to learn:</p><ul><li>Advantages and specifications of the Dynacast A3 Al SIS machine</li><li>Sustainability advantages</li><li>Typical shot material content</li><li>Part examples</li></ul><p>And much more. Enter your details to get instant access.</p><p>From the guide:</p><p><em>“This advancement allows for the efficient production of aluminum parts by directly injecting molten metal into a permanent mold, overcoming previous limitations associated with cold chamber techniques.”</em></p><h3>Please fill out the form to access your copy of the white paper.</h3>

Learn how multi-slide hot chamber aluminum machines improve efficiency and precision in die casting.

Multi-Slide Hot Chamber Aluminum Machine Overview

Download our free white paper on the Multi-Slide Hot Chamber Aluminum Machine to explore the advantages, specifications, and sustainability benefits of the Dynacast A3 Al SIS machine. 

Multi-Slide Hot Chamber Aluminum Machine

<h1>Get your free copy of our Die Casting Design Guide</h1><p>Your biggest component production costs shouldn’t go to waste.</p><p>Yet that’s what many secondary operations will result—in fact, up to 80% of a component’s cost can be attributed to secondary operations that can be made more efficient—or eliminated altogether.</p><p>Get your copy of Die Casting Design Guide. Simply enter your details below.</p><p>Download your free copy of our <strong>Die Casting Design Guide</strong> to learn:</p><ul><li>How to reduce weight on components</li><li>Why wall thickness adds to cost</li><li>What the best draft angle is for inside vs. outside surfaces</li><li>The one critically important factor frequently overlooked by designers</li></ul><p>And much more. Enter your details to get instant access.</p><p>From the guide:</p><p><em>“Design for manufacturing (DFM) is a core methodology that ensures your die cast parts perform to specification and require the minimum of secondary operations. This is important when you consider that these operations can often represent as much as 80% of the component cost.”</em></p><h3>Please fill out the form to access your copy of the white paper. </h3>

Explore design tips and key considerations for creating high-quality, efficient die cast parts.

Your Complete Die Casting Design Guide

Download your free copy of our Die Casting Design Guide to learn how to reduce component costs by minimizing secondary operations and optimizing design for manufacturing. 