Casting Study: Channel and T-shape

Major Selection Criteria: Complex Shape, Corrosion Resistance, Dimensional Precision
Alloy: Zamak 3 (ZL3, ZL0400, ZnAI4, alloy 3)
Application Field: Scientific/Medical Instruments
Application Size: 1) 0.0155 in.x 0.019 in. x 0.100 in.; 2) 0.020 in. x 0.031 in. x 0.100 in.
Surface Finish: As-Cast
Casting Technique: Pressure Die Casting
Source: Dynacast, Inc.

channel2_photo2_caseID71A two-piece holder was developed for a precision scientific instrument. Both castings have detailed features requiring tolerances of +/-0.00025 in. Extrusion could not be used because it could not hold the tolerances, while CNC and wire EDM were not cost effective. By utilising miniature zinc die castings, the instrument manufacturer realised an annual cost savings of $590,000.