Casting Study: Copper Cable Connectors

Major Selection Criteria: Complex Shape, Dimensional Precision, Good Finish
Alloy: Zamak 3 (ZL3, ZL0400, ZnAI4, alloy 3)
Application Field: Communications
Application Size: Male -- 1/2 in. x 9/16 in. x 1-3/16 in.; Female -- 9/16 in. x 3/4 in. x 1-1/4 in.
Surface Finish: Plated
Casting Technique: Pressure Die Casting
Source: Dynacast, Inc., Yorktown Heights, NY

cableconnect2_photo2_caseID128Zinc die casting was choosen to produce a new generation of cable connectors. Critical issues that were met include wall strength to assure durability and to withstand bulk processing, proper matching of draft allowances on the internal surfaces for smooth mating and secure electrical contact. The resulting die cast connector provides 360 deg. Electronic shielding of each pair and gives 4-, 2-, and 1-pair connection options. The exterior connector surfaces are textured for an attractive, uniform, matte finish. The castings are produced with tight dimensional tolerances, flash free and net shape.