zinc die casting

case study
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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Why Choose PHB for Zinc Die Casting?

  • From design concept, to production and packaging, PHB is a world leader in die casting, with clients ranging from large appliance manufacturing companies to the automotive industry
  • PHB solves problems. We can take the most complex design specifications and turn them into a finished product
  • PHB handles all aspects of zinc die casting from mold design and testing, to zinc component manufacturing, finishing, and packaging
PHB’s experience as one of the worlds leading zinc die casting companies spans over 100 years. Since its founding, PHB has evolved into a world class leader utilizing its technological wherewithal and skilled professionals to manufacture high quality die castings. We focus on quality and problem solving in our U.S. based Zinc Molding manufacturing facility. We know that on-time delivery is important to your bottom line, so we make it a top priority.

Zinc Die Casting Capabilities

Our 58 presses range in size from 100 ton to 1000 ton, producing zinc die casting components for low and high volume production programs. PHB provides zinc hot chamber die casting, aluminum-zinc hot or cold chamber high pressure die casting, as well as aluminum die casting. Process monitoring, press side imaging, robotics, MAGMAsoft® flow simulation, perpetual tooling and tool maintenance programs are utilized to extend tool life, reduce cycle times, reduce costs, and provide high quality die castings. From part conception and thorough prototyping, to assembling finished production, PHB can provide, under one central umbrella, the integrated services required to be your complete global manufacturing resource.

zinc alloys

PHB pours vast quantities of aluminum and zinc per year. We are a global leader in manufacturing for die casting. Our highly trained Metallurgists ensure that all alloys meet the specifications through continual chemical and physical analysis.

Our alloys include:

  • Zinc: Zamak 3, 5, and 7
  • Zinc-Aluminum: ZA-8, ZA-12, and ZA-27

Zinc alloys are the easiest to high pressure diecast. They offer high ductility, impact strength, and can be easily plated. Zinc alloys have a lower melting point than aluminum which can assist in promoting longer die life.

ZA alloys are zinc-based die casting materials that have a higher aluminum content than standard zinc alloys. These alloys provide high strength characteristics as well as high hardness and good bearing properties.

MagmaSoft® Zinc Mold Flow Testing

PHB uses the internationally recognized MAGMAsoft® simulation technology to optimize tool design and zinc casting quality.

MAGMAsoft® simulation capabilities provide a better understanding of zinc injection mold filling, solidification, mechanical properties, thermal stresses and distortions, and much more. Fully menu-driven with an integrated solid modeler, CASD interfaces, and extensive databases, MAGMAsoft® provides a complete solution for design, production, and quality departments. Read More About MAGMAsoft®

Prototyping of Zinc Die Cast Parts

PHB can provide components and assemblies in prototyping and low-volume production quantities using a multitude of methods including but not limited to:

  • Plaster Injection Mold Castings
  • CNC Machining and Hog-outs
  • Direct Metal Laser Sintering (DMLS)
  • P-20 Tooling

Zinc Surface Finishing

PHB will manage customer finishing requirements to ensure parts meet specifications in both a timely and cost effective manner.

Our zinc surface finishing includes but is not limited to:

  • Powder Coating (electrostatic application)
  • Wet Paint
  • Chromate
  • E-Coat
  • Electroless Nickel
  • Chrome
  • Silk Screening and Stenciling
  • EMI/RFI Shielding
  • Surface Conditioning (shot and bead blasting)

Our Manufacturing Packaging Process

PHB offers a variety of packaging options for our customers. We can provide packaging layered or by cell. We cater to each individual market all across the globe, and understand that we may have to create something just for you. That’s why we also offer custom designed returnable cardboard or plastic packaging.

Whether you are in the concept stage or ready for production, PHB is ready to help.

choose phb for your zinc die casting needs today

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