PHB Company Profile

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case study
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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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Located in Fairview, Pennsylvania, PHB is a privately held corporation with roots stemming from die casting since 1906. We became incorporated as PHB in 1984. PHB is recognized across the globe as a fully integrated supplier of quality parts and assemblies. With approximately 500 dedicated employees and over 750,000 square feet of floor space, manufacturing capabilities consist of zinc die casting, aluminum die casting, machining, plastic and rubber molding, tool & die, injection molding, and product assembly.

Recognizing that skilled people and technological growth is the keystone for success in today’s global marketplace, PHB continues to commit resources to remain an industry leader. High-tech equipment and machinery feature process monitoring, computer imaging, robotics, CNC and state of the art software including AutoCAD, Pro-E, MAGMAsoft®, CAD/CAM and EDI compatibility. We service many markets including plastics, appliance, telecommunications, electronics, electrical equipment, automotive, transportation, medical, industrial equipment, instrumentation, aerospace and defense industries.

choose phb for your die casting, machining, & injection molding needs