DIE CASTING & PRECISION MANUFACTURING SOLUTIONS. Tel: +1-650-395-8168

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

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

Battery Charger Component Back Side

Home & Office

Door Security Bezel

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

Door Security Bezel

Lighting / Vehicle

LED Heat Sink

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

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

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

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

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

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

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

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

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

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

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

Beer Keg Tap

Sports

Scope

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

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

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

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

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

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

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

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