case studies

Our customers from around the globe value our ability to solve complex manufacturing problems. Our capabilities in prototyping, die casting, injection molding, and machining are unmatched. Our case studies demonstrate the ability of our team to provide superior manufactured products to our customers. We hope your case study will be the next shown here.

Aluminum Die Casting Problems Solved

headlight case study

headlight castings

The Problem

A global leader in automotive lighting came to PHB with the challenge of creating two castings – one for low beams and one for high beams. Because of the complexity in aligning the fixtures (heat sink pads) for the LEDs, prior designs had only allowed them to have three heat-sink pads per casting. Since both the low beams and high beams required six heat sinks, each headlight required four castings. The problem compounded when the mirror design was required for left or right headlights. With the added expense of creating separate tooling for all of the castings, and the additional time and expense involved in aiming these eight castings, our customer realized it was time for a new solution.

The Solution

The challenge in producing the six heatsink pads was to maintain the profile tolerance to the 6 pads to within .4mm to the datum structure. There are 17 individual features at each pad location, or 102 total features per casting that are critical to function. Any missing feature results in a part that our customer cannot fully assemble. PHB utilized the MAGMA process simulation and other camera quality inspection, close tolerance machining, and precision quality control to develop and produce a two-casting headlight assembly for our customer.
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