Casting Study: Traffic Light Housing

Major Selection Criteria: Complex Shape, Corrosion Resistance, Dimensional Precision, Good Finish, Light Weight, Machinability, Mechanical Properties, Thin-Wall Construction
Alloy: Zamak 5 (ZL5, ZL0410, ZnAI4Cu1, alloy 5)
Application Field: Electrical/Electronics
Application Size: >250 g
Surface Finish: E-Coat/Powder Coat
Casting Technique: Pressure Die Casting
Source: ID-Casting France

ima11The 2 parts are used as casing including and protecting the electric system of traffic lights. The material properties provides protection against vandalism and have much longer lifetime than polymer materials and due to thinner sections, lighter than the previous generation which was cast in aluminum. The parts design simplifies maintenance of traffic lights, requiring only one screw to open the housing.

  • Part 1 weight: 1364g
  • Dimension: 427 x113 x 65 mm
  • Part 2 weight:  560g
  • Dimension: 441 x 118 x 43 mm
  • Alloy: ZP5
  • Finishing: Manual picking off, manual deburring, polyeser powder coating

Reasons for choosing zinc alloy:
ZP5 was chosen over other materials for is lower cost, closer dimensional tolerances and good surface finish. The seal requires flatness, solidity and high quality surface. No further machining required. Important reduction of production cost due t hot chamber zinc diecasting with a reasonable machine size (250tonnes)