Large-Scale Design and Manufacturing of Aluminum and Zinc Products
PHB is the preeminent resource for large-scale design and manufacturing of aluminum and zinc products for OEMs and manufacturers located around the globe. Our machinists have extensive experience working with various industries, including automotive, defense, consumer goods, and more. Working as a global OEM for design and manufacturing, and finish machining, PHB offers a precision focus on performance and the capability to handle all project phases entirely in-house. PHB has fully integrated inspection capabilities, so we can manufacture high-performance parts free of any defects while still optimizing efficiency for cost savings. Contact our team today to request a quote for your next project from design to finishing with CNC machining, coatings, etc.
Zinc Casting
Zinc casting is suitable for products that require high ductility, impact strength, and plating. Since zinc has a lower melting point than other metals like aluminum, a zinc die tends to last longer. Zinc-aluminum alloys, however, offer high strength characteristics in addition to good bearing and hardness. Our zinc alloys include Zamak 3, 5, and 7, and our zinc-aluminum alloys include ZA-8, ZA-12, and ZA-27.
Quality Assurance with MAGMAsoft® Simulation Technology
At PHB, we offer precision quality assurance using the MAGMAsoft® simulation technology and its menu-driven integrated solid modeler. Our team implements these simulations in our quality assurance processes to better understand the mechanical properties, solidification, distortions, and thermal stresses of zinc products. MAGMAsoft® is a complete solution for design, production, and quality assurance with zinc and zinc alloys.
Aluminum Casting
PHB has more than 100 years of experience with aluminum die casting and product machining as a global leader in high-quality alloys among international clients. Our facility has 58 presses ranging from 250 to 2000 tons for producing aluminum components for low and high-volume production runs. With MAGMAsoft® flow simulation, robotics, and press-side imaging, quality control is present throughout the process while reducing cycle times and overall cost.
Aluminum Alloys for Lightweight Dimensional Stability
Aluminum parts and components can require complex geometries and thin walls, and our aluminum alloys can meet those mechanical properties while keeping the part corrosion-resistant, conductive, and defect-free. Our aluminum alloys include 360, 380, 383, 413, and A304 K-Alloy.
Large-Scale Design and Aluminum Die Casting for the Automotive Industry
Companies across the world value PHB for our complex problem-solving skills as a global OEM. In the automotive industry, complex problems are present constantly, but our team will look for solutions that can cut costs without sacrificing part integrity and function. For example, we were once contacted by a global automotive lighting company who needed a new solution for headlights.
Our team was able to recognize the problem of aligning heat sink pads for the LEDs in as few castings as possible. Their initial design required four separate castings for each set. With our process simulation and camera quality inspection, we produced a close tolerance solution that only required two castings with six heat sinks each, cutting the total number of castings per pair in half.
High-Volume Zinc Die-Casting for the Consumer Goods Industry
The consumer goods industry requires large production numbers, and our sizable facility can handle manufacturing at that scale while maintaining quality control and dimensional accuracy. All operations from design and prototyping to machining and coating are done in-house in our large scale production lines. Our facility is organized to have different spaces for different types of products to ensure each production process is as efficient as possible.
Parts and products in the consumer goods industry need mass marketplace appeal, so our design and production processes highlight usability alongside quality, safety, and cost-efficiency. Kitchen appliances, for example, use zinc frequently, and our facility can cast about 90 lbs of zinc per minute for products like hand mixers, food processors, toasters, blenders, and more. 22 of our 27 hot chamber zinc machines are automated work centers, so consumer goods production is fast and reliable even at high volumes. With our central die spray system for consistent spray concentration, robotic automation, and Visitrak shot monitoring, high-volume production runs of consumer goods like kitchen appliances maintain the sleek dimensional accuracy customers expect.
Surface Finishing and Other Services
PHB serves customers with complex finishing and machining requirements to ensure that parts and products meet exact specifications promptly. Our surface finishing services include the following:
- Electrostatic Powder Coating
- Wet Paint
- Chromate
- E-Coat
- Electroless Nickel
- Chrome
- Silk Screening and Stenciling
- EMI-RFI Shielding
- Shotblasting
Our close-tolerance CNC machining services include turning, milling, drilling, boring, and tapping. This allows our team to produce high-quality products with dimensional accuracy. Combined with our large facility and knowledgeable staff, this allows us to complete high-volume production with fast turnaround times, all while maintaining testing and quality assurance processes.
Why Choose PHB for Large-Scale Design and Manufacturing of Aluminum and Zinc Products
PHB is a global supplier of aluminum and zinc products for the automotive and consumer goods industries, among many others. We handle initial design, prototyping, early development, and full production of parts and products with high-tech equipment like electronic process monitoring systems and robotics. Our capabilities are designed to drive increased value for our customers, and we are consistently investing in improved processes to increase cost-saving benefits. Get in touch with our team today to get started on your large-scale design and manufacturing of aluminum and zinc products.
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