Applications & Samples
Mouse over the image to see the application summary and how Magic Prevision helped to improve the manufacturability of parts.
Clean Tech
Battery Charger Component Front Side
Manufacturing Process - CNC machining
Material - Yellow brass
Post Processing - Tin plating, santoprene and over molding
Challenges - Critical dimension requirement and tin plating
DFM Recommendation - Remove the radius
Battery Charger Component Back Side
Home & Office
Door Security Bezel
Manufacturing Process - Die Casting
Material - Zinc Alloy
Post Processing - Flattening and powder coating
Challenges - Strict requirement for appearance
DFM Recommendation - Feature changes to better fit assembly
Door Security Bezel
Lighting / Vehicle
LED Heat Sink
Manufacturing Process - Die Casting
Material - Aluminum Alloy ADC12
Post Processing - Tumbling and conversion coating
Challenges - The ejector pin breaks easily while casting
DFM Recommendation - Increase the size of ejector pins and draft angle for easier extraction
Medical
Lens Holder
Manufacturing Process - Die Casting
Material - Aluminum Alloy A383
Post Processing - Micro oxidation
Challenges - Critical requirement of concentricity
DFM Recommendation - Increase the wall thickness to prevent warp
X-ray Film Tray
Manufacturing Process - Die Casting
Material - Magnesium Alloy AZ91D
Post Processing - Machining, powder coating and printing
Challenges - Special machining request, high cosmetics requirement
DFM Recommendation - Increase wall thickness
Medical Sensor Housing
Manufacturing Process - Die Casting
Material - Zinc Alloy
Post Processing - Matte chromate plating
Challenges - Critical plating requirement
DFM Recommendation - Increase the ribs
Optical
High Speed Motor Case
Manufacturing Process - Extrusion
Material - Aluminum Alloy
Post Processing - Anodising
Challenges - Complex shape and precise dimensions
DFM Recommendation - Increase the wall thickness
Lens Holder
Manufacturing Process - Die Casting
Material - Magnesium Alloy AZ91D
Post Processing - Black conversion coating
Challenges - Precise dimensions, tool requires 4 slides
DFM Recommendation - Increase wall thickness to prevent warp
Spectral Measurement Part
Manufacturing Process - Die Casting
Material - Aluminum Alloy A380
Post Processing - Anodising and liquid painting
Challenges - Precise dimensions, complex shape for casting
DFM Recommendation - Increase the draft angle
High Strength Plastic Gear
Manufacturing Process - Injection molding
Material - PC/ABS blend
Post Processing - Over-mold for the gear
Challenges - Precise dimensions, difficult shape to mold
DFM Reccomendation - Increase the ribs
Range Finder
Manufacturing Process - Die Casting
Material - Magnesium alloy AZ91D
Post Processing - Machining and ED coating
Challenges - Highly precise dimensions
DFM Recommendation - Increase the draft angle
Lens Housing
Manufacturing Process - Gravity Casting
Material - Aluminum Alloy A356
Post Processing - Machining and anodising
Challenges - Highly precise dimensions
DFM Recommendation - Increase the draft angle and wall thickness
Others
Beer Keg Tap
Manufacturing Process - Die Casting
Material - Aluminum Alloy ADC12
Post Processing - PVD coating
Challenges - Critical appearance requirement, complex shape for casting
DFM Recommendation - Increase the wall thickness on all edges
Beer Keg Tap
Sports
Scope
Manufacturing Process - Aluminum Extrusion
Material - Aluminum 6061-T6
Post Processing - Turning, machining, anodising and engraving
Challenges - Highly precise dimensions and cosmetics requirements
DFM Recommendation - Increase the wall thickness
Hunting Scope
Manufacturing Process - Die Casting
Material - Magnesium Alloy AZ91D
Post Processing - Grinding, machining and liquid painting
Challenges - Tool with 4 slides, difficult to cast, critical requirement for painting
DFM Recommendation - Increase wall thickness for easier casting
Hunting Scope
Manufacturing Process - Gravity Casting
Material - Aluminum Alloy A356
Post Processing - Grinding, deburring and flattening
Challenges - Critical dimensions requirement
DFM Recommendation - Increase wall thickness for easier casting
Telecom and Networking
High Performance Heat Sink
Manufacturing Process - Die Casting
Material - Aluminum Alloy A356
Post Processing - Grinding and Sand Blasting
Challenges - Special material for die casting, high flatness requirement
DFM Recommendation - Increase wall thickness for easier casting
Eye Patch
Manufacturing Process - Injection Molding
Material - Polycarbonate
Post Processing - Polish
Challenges - Highly precise dimensions requirement
DFM Recommendation - Increase wall thickness
Test Equipment
Camera Housing
Manufacturing Process - Die Casting
Material - Aluminum Alloy 6061-T6
Post Processing - Machining, ED Coating
Challenges - Special threading, high cosmetics requirement
DFM Recommendation - Increase wall thickness
Tools
Cam Block
Manufacturing Process - Forging, Machining
Material - Aluminum Bronze
Post Processing - Milling, Engraving
Challenges - Difficulty in machining high hardness part
DFM Recommendation - Increase radius
Transportation
Precision Encoder Component
Manufacturing Process - Die Casting
Material - Aluminum Alloy A380
Post Processing - Turning, Milling, Surtec 650 Conversion Coating
Challenges - Precise dimension requirement
DFM Recommendation - Reduce material stock to avoid porosity after machining
