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Dynacast - Resources - L1

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Dynacast transforms ideas into high-precision metal components. Leveraging innovative technology, unmatched engineering expertise, and the most precise die casting capabilities in the world, we are the preferred metal manufacturer for industry leaders looking for tailored solutions worldwide.

Dynacast Company Overview 2025

<p>When miniaturization meets industrial-grade durability, the stakes are high. For SICK, a global leader in sensor technology, designing the <strong>picoScan100 2D LiDAR sensor</strong> meant pushing the limits of engineering—requiring a manufacturing partner to deliver precision, complexity, and reliability in one of the smallest, most sensitive components on the market.</p><h2><strong>The Challenge: Tiny Sensor, Big Demands</strong></h2><p>SICK's picoScan100 posed a unique engineering dilemma. The <strong>sensor housing</strong> had to be <strong>incredibly small</strong>, <strong>mechanically intricate</strong>, and <strong>tolerant to the rigors of industrial environments</strong>—all while ensuring <strong>exact internal tolerances</strong> for stable lens placement. Complicating matters further were <strong>minimal draft angles</strong> and the necessity for <strong>flawless shot accuracy</strong>, making traditional manufacturing approaches difficult and error prone.</p><h2><strong>The Solution: Precision Engineering from Concept to Completion</strong></h2><p>Recognizing the sensor’s complexity, SICK turned to Dynacast for a solution that would combine <strong>engineering expertise, process control, and collaborative innovation</strong>.</p><p><strong>1. Collaborative Design Support</strong></p><p>Dynacast was brought in early to help optimize the housing’s geometry, ensuring <strong>manufacturability without compromising function</strong>. This proactive partnership allowed design and production to align from day one.</p><p><strong>2. Simulation-Driven Precision</strong></p><p>By leveraging simulation software alongside deep die casting expertise, Dynacast fine-tuned the tooling and process flow—<strong>mitigating risks</strong> before production began.</p><p><strong>3. Precision Microcasting</strong></p><p>With a focus on <strong>gating and overflow design</strong>, Dynacast achieved flawless mold filling—ensuring dimensional integrity and consistent part quality at micro scales.</p><h2><strong>The Results: Flawless Execution, Satisfied Partners</strong></h2><p>SICK’s expectations were not only met—they were exceeded.</p><ul><li><strong>Seamless Integration</strong>: The sensor housing was implemented smoothly, <strong>without the need for post-production corrections.</strong></li><li><strong>Perfect Performance</strong>: Every unit met the stringent performance requirements essential to the LiDAR system’s functionality.</li><li><strong>Customer Satisfaction</strong>: SICK lauded the collaboration and outcome, with Dynacast recognized for a well-executed strategy that delivered value from start to finish.</li></ul><p><strong>“[Dynacast delivered] smooth implementation of the entire project without additional corrections.”</strong> – <em>SICK</em></p><p><strong>“SICK was a very satisfied customer thanks to our implementation strategy.”</strong><br />– <em>Markus Verini, Business Development Manager, Dynacast Europe</em></p>

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Discover how Dynacast provided high-precision die-cast components for SICK’s LiDAR sensors, ensuring optimal performance and reliability.

Precision Die Casting for SICK’s LiDAR Sensor | Dynacast

Discover how Dynacast partnered with SICK to deliver flawless, high-precision sensor housing for the picoScan100 2D LiDAR—overcoming extreme design challenges through early collaboration, simulation-driven engineering, and micro-scale casting expertise.

How Dynacast Delivered Precision for SICK’s LiDAR Sensor

<h2><strong>The Challenge: Plant Closure Opens a Complex Mission</strong></h2><p>When a long-established plant shut down, a leading player in the security products industry was faced with an urgent and complicated transition. The facility's aging infrastructure, high labor costs, and inefficient tooling utilization had made in-house production unsustainable. With most of the tooling contributing minimally to overall production spend, the decision was made to relocate dozens of tools—an ambitious move requiring speed, coordination, and technical precision.</p><p>But the road ahead wasn’t simple. Rising cost pressures, logistical strain from shipping dozens of tools monthly, and unclear tooling documentation posed real threats to success. On top of that, inconsistent sampling protocols and missing information for secondary operations risked slowing everything down.</p><h2><strong>The Solution: A Smart Shift to Efficiency and Control</strong></h2><p>Dynacast’s focus was not just on moving tools—it was on optimizing them for better performance and building a foundation for long-term value.</p><p>Dynacast brought deep <strong>expertise in precision casting</strong>, using an engineering-first approach to ensure every part was thoughtfully designed and accurately cast for optimal performance. This technical rigor was matched by <strong>speed without compromise</strong>—the team acted swiftly to meet tight timelines without ever cutting corners, maintaining the highest quality standards throughout. What truly set the project apart, however, was the <strong>partnership dynamic</strong>.</p><h2><strong>The Implementation: Prioritizing Medium-to-Low Volume Parts</strong></h2><p>Thanks to compatibility with the customer’s existing equipment platforms, the Dynacast team was able to integrate the transferred tools with minimal disruption—often getting machines running within a day or two. Dynacast focused efforts where it mattered most: medium-to-low volume parts that offered the greatest strategic value, while also keeping future high-volume opportunities in view.</p><h2><strong>Capabilities That Count</strong></h2><p>The equipment used at Dynacast represented a major upgrade from the aging machines of previous suppliers. Our ability to build both tools and machines in-house gave the team unique control over quality and lead times. And when added flexibility was needed, our collaboration with global teams—including engineering support from Asia—ensured nothing slowed progress.</p><h2><strong>The Results: Partnership, Performance, and Future Potential</strong></h2><p>Weekly check-ins, pilot runs, and a commitment to shared success laid the groundwork for a lasting strategic relationship. By avoiding supply chain disruptions during a critical transition, Dynacast not only ensured continuity but also improved tooling performance—extending tool life and setting the stage for future growth and opportunities.</p><p></p>

Learn how Dynacast managed a complex tooling move after a plant closure, ensuring uninterrupted production and timely delivery.

Tooling Transfer After Plant Shutdown | Dynacast Case Study

In this case study, you'll see how Dynacast tackled the urgent challenges of a plant closure for a major security products company—moving dozens of tools quickly and precisely while improving overall efficiency. You'll learn how their engineering-first approach and close collaboration helped turn a complex transition into a long-term strategic win.

How Dynacast Orchestrated a Complex Tooling Move

<h2><strong>The Challenge: A Race Against Time and Quality</strong></h2><p>Faced with new federal incentives aimed at reshoring production to the U.S., a leading solar mounting system manufacturer encountered a major roadblock. Their previous die casting supplier couldn’t deliver the speed, quality, or production volume needed to capitalize on the opportunity. Poor production output, neglected tool maintenance, and lack of support put both the project timeline and valuable tax incentives at risk.</p><h2><strong>The Objective: Onshore, Scale, and Elevate Quality</strong></h2><p>The customer’s goals were clear: move production stateside, improve component quality, and ramp up capacity to meet a growing market. But meeting these targets meant overcoming the obstacles of a struggling supplier and executing a tooling transfer that wouldn't disrupt the manufacturing timeline.</p><h2><strong>The Solution: A Strategic Partnership Built for Performance</strong></h2><p>The Dynacast team quickly developed a plan to bring the customer's program back on track.</p><p>Dynacast prioritized a <strong>rapid, quality-driven onshoring</strong> process, recognizing the urgency of the situation. The team executed a seamless tooling transfer and ramped up production, enabling the immediate delivery of high-quality parts from day one.</p><p>In addition, <strong>supply chain simplification</strong> was a key focus. Dynacast offered a range of value-added services, including in-house assembly, custom fixtures, and specialized packaging.</p><h2><strong>Engineering in Action: From On-Site Visits to Dynacast Lake Forest</strong></h2><p>The success of this transition hinged on careful engineering and collaboration:</p><ul><li><strong>A Hands-On, Collaborative Approach</strong>: Dynacast’s Lake Forest engineering team worked closely with the customer’s technical staff to understand exact product and tooling requirements. The process began with an on-site review at the outgoing supplier’s facility and continued with a detailed inspection once the tools arrived at Dynacast.</li><li><strong>Expert Tool Refurbishment &amp; Integration</strong>: The tools were thoroughly cleaned, refurbished, and, where needed, modified to suit Dynacast’s production environment. This careful preparation ensured a smooth handoff with minimal production disruption.</li></ul><h2><strong>The Results: Onshoring Success with Room to Grow</strong></h2><p>The solar manufacturer successfully moved production to the U.S., qualifying for tax incentives and dramatically improving part quality. Beyond immediate gains, the company also laid the groundwork for broader reshoring initiatives.</p>

Discover how a solar company leveraged U.S. tax incentives by relocating manufacturing domestically with Dynacast, enhancing efficiency and cost savings.

Onshoring Solar Manufacturing | Dynacast Case Study

Discover how Dynacast helped a solar mounting system manufacturer overcome critical supplier issues just in time to meet federal reshoring incentives. You'll see how fast, high-quality production, smart engineering, and close collaboration enabled a seamless transition to U.S.-based manufacturing—paving the way for long-term growth and success.

How This Solar Company Capitalized on Tax Incentives By Onshoring

<h2><strong>The Challenge: Ensuring Strict Quality in Safety-Critical Die Cast Tool Transfers</strong></h2><p>A prominent manufacturer of air brake systems for heavy-duty trucks needed a reliable die casting partner to ensure the continuity and quality of their safety-critical components. With their production reliant on zinc die cast parts, they were faced with several critical tools needing to be transferred with zero disruption to their manufacturing schedule.</p><p>The company turned to Dynacast’s Peterborough facility, having previously experienced the team's technical reliability and industry expertise.</p><h2><strong>The Solution: Expertise, Communication, and Precision Engineering</strong></h2><p>Dynacast’s longstanding partnership with the customer laid the groundwork for a tooling transfer that was both technically sound and operationally seamless. The project’s success hinged on three pillars:</p><ol><li><strong>Open Communication and Dedicated Support</strong><br />Clear, proactive dialogue ensured alignment between both teams. Dynacast provided continuous technical support throughout the transition, enabling fast decision-making and issue resolution.</li><li><strong>Flawless Tooling Integration</strong><br />The transfer process was meticulously managed, with the tooling relocated directly to the Peterborough site for immediate integration into production.</li><li><strong>Relentless Focus on Quality</strong><br />With safety-critical parts in scope, Dynacast maintained stringent quality standards every step of the way—protecting both performance and customer trust.</li></ol><h2><strong>Engineering Highlights: Solving for the Unknown</strong></h2><p><strong>The absence of existing CAD files or tool documentation added complexity to the situation.</strong></p><p>The engineering team began with a <strong>comprehensive tool assessment</strong>, manually evaluating each tool to determine its condition, shot life, and overall suitability for continued use. With no existing CAD data or tool files, this hands-on inspection was critical to ensuring a reliable production setup.</p><p>Following the assessment, the team executed a <strong>direct facility transfer</strong>, transporting the tools straight to Dynacast’s Peterborough facility.</p><h2><strong>The Outcome: A Smooth Die Cast Tooling Transfer</strong></h2><p>The tooling transfer was completed successfully and fully integrated into production—without causing any disruption to the customer’s schedule. From the outset, Dynacast maintained the high-quality standards required for safety-critical components, ensuring reliable performance and consistency from day one.</p>

Discover how Dynacast ensured seamless production of safety-critical air brake components through transferring die cast tooling.

Tooling Transfer for Air Brake Parts | Dynacast Case Study

In this case study, you’ll learn how Dynacast helped a leading air brake system manufacturer seamlessly transfer critical die cast tooling—without disrupting production or compromising safety. You’ll see how clear communication, hands-on engineering, and a relentless focus on quality made it possible to maintain high performance and trust in a safety-critical environment.

How Dynacast Seamlessly Transferred Safety-Critical Tooling

<p>As industries continue to push the boundaries of lightweight metal components without compromising safety, a breakthrough material is now playing a pivotal role in Dynacast Austria’s latest manufacturing advancement: <strong>MgCarbonit91</strong>. This innovative magnesium alloy combines exceptional castability with a unique fire-retardant capability—contributing to safer, lighter parts produced through <strong>thixomolding</strong>.</p><h2><strong>MgCarbonit91: A High-Strength, Fire-Retardant Magnesium Alloy</strong></h2><p>Traditionally, the challenge with magnesium alloys has been striking the right balance between flame resistance and mechanical strength. While earlier compositions have improved ignition temperatures to meet flame-resistance standards, they often did so at the expense of structural performance—especially when compared to the widely used MgAZ91 alloy.</p><p>MgCarbonit91 solves this challenge. <strong>By adding carbon nanoparticles, it maintains the strong mechanical properties of traditional magnesium alloys. The result is a material that is </strong><strong>flame-resistant</strong><strong>.</strong></p><h2><strong>Thixomolding's Impact on </strong><strong>Aerospace, Electronics and More</strong></h2><p>Dynacast Austria is leveraging the benefits of MgCarbonit91 in its new semi-solid metal processing technique, Dynathixo, which is ideal for producing high-precision magnesium parts. MgCarbonit91’s thixomoldability ensures smooth flow, minimal porosity, and consistent surface finish—even in intricate mold designs.</p><p>This development positions Austria as a central hub in Dynacast’s global network for magnesium applications, particularly in high-stakes sectors like aerospace, electronics, and energy storage.</p><h2><strong>MgCarbonit91 vs. Aluminum</strong></h2><p>Weighing in at just two-thirds the density of aluminum, MgCarbonit91 enables substantial weight reductions without compromising strength or safety. Its properties make it ideal for use in aircraft interiors and other applications where both fire safety and structural integrity are paramount.</p><h3><strong>Key characteristics of MgCarbonit91:</strong></h3><ul><li>Self-extinguishing for enhanced fire safety</li><li>Excellent casting and thixomolding process compatibility</li><li>Strong mechanical performance</li><li>Lightweight—approximately 33% lighter than aluminum</li><li>Suitable for high-risk applications</li></ul><h3><strong>Typical applications include:</strong></h3><ul><li>Battery housings</li><li>Aircraft seat backs and footrests</li><li>Display housings and table arms</li><li>Electronic enclosures and control boxes</li></ul><h2><strong>Innovation That Protects and Performs</strong></h2><p>By integrating MgCarbonit91 into its thixomolding operations, <a href="https://www.dynacast.com/en-us/locations/dynacast-austria">Dynacast Austria</a> is furthering its commitment to innovative materials that offer both performance and protection. As safety regulations grow more stringent and demand for lightweight metals continues to rise, MgCarbonit91 stands out as a next-generation alloy helping to shape the future of precision magnesium manufacturing.</p>

Manufacturing employee operating equipment in Peterborough

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Discover how Dynacast's magnesium alloys achieve fire resistance, offering lightweight and safe solutions for advanced engineering applications.

Fireproof Magnesium Alloy Explained | Dynacast

This article introduces MgCarbonit91, a groundbreaking fire-retardant magnesium alloy used in Dynacast Austria's advanced thixomolding process. Readers can expect to learn how this material achieves a rare combination of lightweight strength, fire safety, and excellent moldability, making it ideal for high-performance applications in aerospace, electronics, and energy storage.

What Makes This Magnesium Alloy Fireproof?

<p>Injection metal assembly (IMA) is a 4 step process that replaces and outperforms conventional methods of assembly including crimping, soldering, staking, and welding. IMA is well-suited for assembling components of different shapes, sizes, and materials, including metals, ceramics, glass, fibers, paper, elastomers, and plastics.</p>

Injection metal assembly (IMA) is a 4 step process that replaces and outperforms conventional methods of assembly including crimping, soldering, staking, and welding. IMA is well-suited for assembling components of different shapes, sizes, and materials, including metals, ceramics, glass, fibers, paper, elastomers, and plastics.

What Is Injected Metal Assembly?

<p>Dynacast is able to create custom precision components with tolerances of +/-0.02mm. With our multi-slide process, we can create net shape parts typically without secondary operations—including internal and external threads. The end result is a high-speed, temperature-controlled process that produces thin-walled components so complex in geometry that they would need to be manufactured from two or more pieces if other methods of die casting were used. If you require small complex components, multi-slide die casting may be your best solution. Contact our engineering team to get started on your project.</p>

Dynacast is able to create custom precision components with tolerances of +/-0.02mm. With our multi-slide process, we can create net shape parts typically without secondary operations—including internal and external threads. The end result is a high-speed, temperature-controlled process that produces thin-walled components so complex in geometry that they would need to be manufactured from two or more pieces if other methods of die casting were used. If you require small complex components, multi-slide die casting may be your best solution. Contact our engineering team to get started on your project.

Multi-Slide Die Casting Process

Dynacast offers proprietary multi-slide, hot chamber aluminum die casting. This high-speed process has production capabilities of up to 10 cycles per minute, while ensuring uniformity across parts.

Multi-Slide Aluminum Die Casting

Dynacast Peterborough is known for its multi-slide technology, standard die casting with integrated automation, and IMA (Injected Metal Assembly) precision zinc manufacturing. The Peterborough facility is dedicated to designing, building, manufacturing, and delivering quality die cast components. 

Dynacast Peterborough Facility Spotlight

<p>Dynacast Lake Forest facility is dedicated to die casting zinc alloys with both conventional and multi-slide machines, as well as die casting aluminum alloys. Dynacast Lake Forest is equipped with state-of-the-art technology to provide the highest quality die casting parts. </p>

Dynacast Lake Forest facility is dedicated to die casting zinc alloys with both conventional and multi-slide machines, as well as die casting aluminum alloys. Dynacast Lake Forest is equipped with state-of-the-art technology to provide the highest quality die casting parts. 

Dynacast Lake Forest Facility Spotlight

<p>Take a journey through the Dynacast Peterborough tool room. In-house die cast tool design offers companies greater flexibility, control, customization, and responsiveness. It streamlines the production process, improves collaboration between design and production teams, and contributes to long-term cost savings and product quality enhancement. </p>

Take a journey through the Dynacast Peterborough tool room. In-house die cast tool design offers companies greater flexibility, control, customization, and responsiveness. It streamlines the production process, improves collaboration between design and production teams, and contributes to long-term cost savings and product quality enhancement. 

Die Cast Tooling & Engineering Capabilities

<p>From material selection to choosing the optimal process and eliminating secondary operations, Dynacast’s engineers work with each customer during the design process to make sure the part design will succeed in mass production. One of the major differentiators that distinguish Dynacast from other die casting companies is the quality of our tooling. All of our dies are made using a specific steel type with an additional heat treatment that can withstand a high number of shots and maintain the integrity of the component being manufactured. With little downtime, our tools create consistent, complex parts shot after shot and last longer than most of our competitors. Our multi-slide tools often come with a lifetime warranty.</p>

From material selection to choosing the optimal process and eliminating secondary operations, Dynacast’s engineers work with each customer during the design process to make sure the part design will succeed in mass production. One of the major differentiators that distinguish Dynacast from other die casting companies is the quality of our tooling. All of our dies are made using a specific steel type with an additional heat treatment that can withstand a high number of shots and maintain the integrity of the component being manufactured. With little downtime, our tools create consistent, complex parts shot after shot and last longer than most of our competitors. Our multi-slide tools often come with a lifetime warranty.

Benefits of Dynacast Tooling & Engineering Expertise

In this video, discover the fully-automated conventional zinc die cast cell with in-line robotic trimming. Conventional die cast tooling is designed with single or multiple cavities. The tool is designed to be efficient and cut down on secondary operations which help lower costs. Other benefits of conventional die cast tooling, include:<p></p><ul><li>Dies that are designed to efficiently manage high volume production</li><li>Net shape die casting, with design focused to avoid secondary operations</li><li>Steel braced dies to aid in the longevity of the tool</li><li>Efficient production with properly planned cooling and water lines</li></ul>

In this video, discover the fully-automated conventional zinc die cast cell with in-line robotic trimming. 

Conventional die cast tooling is designed with single or multiple cavities. The tool is designed to be efficient and cut down on secondary operations which help lower costs. Other benefits of conventional die cast tooling, include: 

Dies that are designed to efficiently manage high volume production 
Net shape die casting, with design focused to avoid secondary operations 
Steel braced dies to aid in the longevity of the tool 
Efficient production with properly planned cooling and water lines 

Conventional Zinc Die Casting Process

<h4>All the benefits, none of the drawbacks</h4><p>There’s nothing better than sitting in the sun on a gorgeous deck. Properly maintained, a deck is an extension of your living space and an asset to any property. But as any deck owner knows: they can be a lot of work. Year-in, year-out, wooden decks demand regular maintenance—from resurfacing to varnishing. And if they don’t get it, they can become dangerous eyesores.</p><p>Of course, until now, wood has always been the default material used for decks. But not any longer if SigmaDek has anything to do with it. We spent some time with Brian Boettger, VP Product Development to find out more.</p><h4>Wanted: A metal-tile maker</h4><p>Butlers had seen Giles Miller’s work and wanted a brass finish for its café counter. The designers had produced a brass finish on ceramic tiles before, but they were worried ceramic wouldn’t survive the demands of a busy airport (where bags and luggage trolleys can deliver quite a pounding). So they thought of making metal tiles and started looking at metal manufacturing processes.</p><p>What they wanted was a 40mm-square metal tile with a chamfered face, and with one corner 20mm higher than the opposing diagonal—so when it’s rotated the light catches it in different ways. “When we started looking for a manufacturer there were a few other metal-casting companies but Dynacast was the most helpful,” says the designer Kirstie Little, “and the only one able to make the thousands of tiles we needed in the short lead-time we had.”</p><h3>From drawing board to café counter</h3><p>The designers made a trip to Dynacast’s UK plant in Welshpool, Wales, where sales manager John Jackson, who, like the rest of the sales team, is also an experienced engineer, gave them a factory tour. “We showed John the drawings and he was really helpful about the processes and what can and can’t be done,” says Kirstie. “He told us how to get the right finishes and how the tiles could be fixed on with a screw system at the back, as they were a bit too heavy to be stuck on. Having John involved right from the start meant everything went a lot quicker.”</p><p>For John this was an intriguing project. He knew zinc would be the best metal for the casting as it’s good at taking surface finishes. He also knew the client wanted a uniform brass finish, so after the initial copper coat, he recommended a nickel plating to give a white surface that would take the brass layer well on top.</p><p>The tiles were to be fixed onto panels by Giles Miller in its production space before being sent off to the client for installation. The assemblers needed to be able to take any tile out of the box and know the spacing would be absolutely consistent, so it was vital there was no machining variation between the tiles. Dynacast also ensured the plating was even and didn’t build up on sharp edges and corners. No machining marks were allowed to ruin the finish. And a stringent right-first-time approach meant there was no need for subsequent trimming or polishing.</p><h3>A showcase product</h3><p>Thanks to great communication between the client, Dynacast and the plating subcontractor, the project was delivered on time in just seven weeks. Kirstie says that Butlers “absolutely loved” the result and they’re in talks about another potential project. At the same time the die cast metal tiles are an important extension of Giles Miller’s product range and the designers have already been chatting to John about other shapes and different finishes such as antique brass and black nickel.</p><p>And this unusual project has also given John Jackson—and Dynacast—a new way of showing people what can be done with zinc die casting and surface finishes. “If you can deliver something as cosmetically challenging and visually stunning as this in such a short space of time, it really does open up new opportunities,” he says. “I hadn’t thought of using zinc die casting in this way before, and this project shows that we are only limited by our imagination in how we apply it.”</p>

Explore how advanced die cast plating techniques improve surface quality, durability, and performance.

Enhance Die Cast Plating for Superior Finish

Explore how Dynacast's expertise in zinc die casting and superior plating solutions delivered stunning, uniform brass finishes for a high-profile café counter project, showcasing the versatility and aesthetic potential of metal tiles.

Superior Die Cast Plating

<h2>Moving from Plastic to Metal for Ultimate Part Strength</h2><p>Dynacast was presented with manufacturing an electrical motor pinion. The pinion is an integral part in the overall function of the motor, requiring precise tolerances and high strength material.</p><h3>Plastic versus metal components</h3><p>Initially, the customer designed the part in plastic, but once the part was put into testing, heat and distress requirements caused the part to fail. Additionally, the plastic production process failed to meet technical requirements needed for part performance. The customer required tighter tolerances and complex component design for the electro-mechanical mechanism to achieve optimal performance, so they turned to Dynacast for a solution.</p><p></p><img asset_uid="bltb31a0308361cb55d" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/bltb31a0308361cb55d/670690310d6784b9be23e708/Picture15.jpg" alt="Picture15.jpg" height="auto"/><h3>Prototyping and metal solutions</h3><p>With material strength being the customer’s main priority, Dynacast utilized a prototype tool to test various alloys, allowing design engineers the ability to quickly and efficiently test for performance, and craft even better components.</p><p>The first prototypes were made using Zamak 5. Zinc alloy 5 is the most widely used zinc alloy in Europe and is known for its hardness and high-strength properties. But despite an improvement from plastic, the resistance was not enough. Zamak 2 was tested next, due to a higher resistance and higher hardness, however, the design engineers knew there was another option.</p><p><strong>EZAC®</strong>. This hot chamber zinc alloy has superior creep resistance, high yield strength, high hardness, and low melting temperatures. While zinc has always been known for its high strength, the addition of EZAC® to the list of alloys Dynacast can cast makes this zinc alloy more suitable for applications like this pinion that require high surface hardness.</p><p>The customer put Dynacast’s EZAC castings under severe endurance testing and were extremely pleased with the new material, making it an easy choice to switch from plastic injection molding to die casting.</p><p>If you are looking for a partnership to help you apply new tools and technologies, or help you fully realize your design vision, let us help you move your business forward, contact our team today to get the conversation started.</p>

Learn how moving from plastic to metal die casting boosts part strength, durability, and performance.

Move from Plastic to Metal for Ultimate Part Strength

Dynacast helped a customer improve the strength and performance of an electrical motor pinion by transitioning from plastic to a high-strength EZAC® zinc alloy, ensuring tighter tolerances and better endurance under extreme conditions.

Moving from Plastic to Metal for Ultimate Part Strength

<h3>Machining Conversion to Die Casting</h3><p>If you’ve seen the breathtaking aerial footage drone cameras are capable of, you know it’s possible to get film-like, smooth video from today’s go-anywhere cameras. GoPro needed to affordably deliver that same, incredible stability to adventure athletes on the ground, underwater, or in flight—instead of the bounced-around “shaky cam” look that’s inevitable with a handheld device.</p><h3>Bringing Video Down to Earth</h3><p>Without stabilization, the jarring agitation of any handheld video is obvious on screen.</p><p>It’s even worse for adventure athletes: the conditions are anywhere from unpredictable to extreme; there’s not always a logical place to mount the camera; and “just stand still” is a foreign concept. For these video creators, stabilizing equipment is key.</p><p>GoPro already had a stabilization system for use with a quadcopter-style drone, but customers love to get close-up footage right inside the action.</p><p>The company decided to re-purpose the drone mounting component into a piece customers could use to attach GoPro cameras to handheld and body-worn stabilizers instead.</p><h3>Epic Versatility</h3><p>“The products we make endure a wide variety of uses,” explains Matt Thomas, Mechanical Engineering Manager for GoPro accessories. “Everything from skiing to SCUBA diving to chasing your kids through a park.”</p><p>That meant the mount would have to be strong—and for consumer use, it would need to provide cost savings through thousands of units and many years. In order to expedite time to market, GoPro’s designers initially specified the mount as an all-machined metal component.</p><p>“While that was the quickest way for us to get to market,” says Thomas, “it was also more expensive. So in parallel, we investigated a longer term, more cost-friendly option.”</p><p><strong>To determine the optimal materials and processes to reduce costs for the replacement part GoPro wanted, the team brought in Dynacast.</strong></p><h3>Casting Decisions</h3><p>“We utilized Dynacast’s services in the past on a number of projects, and they’ve become one of our top tier suppliers,” says Thomas. The two companies had also worked together in sessions that Dynacast held to explore cost reduction and manufacturability improvements. And the first thing they agreed on was minimizing the costs related to processing.</p><p>“Extrusion is great for making a two-dimensional part, but then when you add other features to it, you have to machine it as a secondary process, and that’s what adds the cost,” says Bill Heilman of Dynacast. “We told them, you don’t have to add machining. We can just cast it in that shape.”</p><h3>Handle—With Care</h3><p>The GoPro team’s overarching goal was to reduce the cost but had other requirements for the part too. “We needed strength and a lightweight component. Something that would handle a variety of environmental situations,” says Thomas.</p><p>And, since the part is a handle that people would operate with their fingers (often in extreme conditions, and maybe not with the gentlest touch), the team needed to make sure that the feel would be acceptable to the end user.</p><p>Because materials have different options for surface treatments, keeping the post processing work to a minimum was important, with respect to secondary polishing and machining of the components—and getting the precise anodization color. They ultimately cast it in aluminum, to match the existing parts on the mount—but also to achieve their cost-reduction goals.</p><h3>Material Selection</h3><p>“We tell customers, ‘Don’t assume because you chose one particular manufacturing process that that’s the only way to make the part,’” says Dynacast’s Heilman.</p><p>Matt Thomas would agree. “When we first started, the cast part represented an approximately 50% savings over the machined part”—making die cast aluminum a clear choice for both cost reduction and manufacturability goals.</p><p>“It’s great to see product out on the market and being sold,” says Thomas. “Dynacast is very responsive, very timely with their communication, easy to work with. It’s just the ease of collaboration in taking the design from concept to tooling.”</p><p>If you are looking for a partnership to help you apply new tools and technologies, or help you fully realize your design vision, let us help you move your business forward, contact our team today to get the conversation started.</p>

Discover how converting from machining to die casting lowers costs, improves speed, and boosts precision.

Switch from Machining to Die Casting for Efficiency

This case study highlights how GoPro partnered with Dynacast to convert a machined metal component into a die-cast aluminum part, resulting in significant cost savings and improved manufacturability for their camera stabilization mounts.

Machining Conversion to Die Casting

<h2>From Plastic to Zinc Die Casting</h2><p>"We’re a really small startup. Dynacast made sure we could get to market on time." - Andrea Perdomo, Revolar</p><h3>A Magic Button</h3><p>In vulnerable situations, the difference between feeling powerless and being secure can come down to one question: how quickly could you signal someone for help if you needed it?</p><p>Most people carry smartphones with them outside the house. But using one to SOS in unexpected situations isn’t exactly instantaneous.</p><p>Fumbling with a dial pad, calling an emergency number, and explaining the potential threat can add many adrenaline-filled moments—not to mention confusion about the person’s precise location.</p><p>This complexity is what led Revolar cofounders Jacqueline Ros and Andrea Perdomo—both of whom have close relatives who survived traumatic personal danger—to come to a shared epiphany.</p><p>“If only they’d had a ‘magic button’ they could have pressed to let us know they needed help, they would have been able to avoid so much,” says Perdomo.</p><p>And the Revolar safety device was born. Clipped onto keychains, backpacks or purses, one click sends an “all clear” check-in to chosen contacts, while additional clicks escalate the urgency, so contacts can help—or send first responders.</p><p>The pair bootstrapped their startup, funded it with a Kickstarter campaign, and landed outside funding, before getting coveted shelf space for their first-generation device in Brookstone, Target, Amazon, and BestBuy. But months of testing revealed that consumers wanted a second-generation product with a smaller, more premium form factor that would fit right into their lifestyle. Consumers wanted the button to feel less like a device and more like an accessory.</p><h3>Manufacturing Fashion</h3><p>To arrive at the ideal specs, Dynacast took Revolar through DFM (design for manufacturing) sessions covering process, material, and finishes.</p><p>“This next-generation device needed a stronger part,” says Dan Taylor of Dynacast. “It needed a feeling of higher quality, which a lot of our customers like—that heavier, metallic part in their hand—because it feels much stronger than plastic parts.”</p><p>Dynacast’s recommendation was zinc, which for die casting applications can be made thinner, more intricate, and more complex even at incredibly small sizes.</p><p></p><p></p><figure style="text-align: left"><div data-img-caption-container="true" style="display: inline-block; text-align: center;"><img alt="Picture1.jpg" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt3380e4080389a964/6706036e0d6784c13723e172/Picture1.jpg" height="auto" style="text-align: left;" /></div></figure><h3>Design Down to The Wire</h3><p>“We had a plating ‘recipe’ for the finish of this part, whether it was sandblasting it, bead blasting it, then adding different types of copper-nickel plating,” says Dynacast’s Taylor. But Revolar hadn’t yet confirmed the finish.</p><p>Then they visited Dynacast’s plant in Batam, Indonesia, where they looked at some automotive key fob parts that were about the same size as Revolar’s design. Says Taylor, “They liked the components, which were beautiful and small, and the finish, which was a very shiny, satin chrome. They said, ‘That’s what we want.’”</p><p>It took time for tooling to begin, precisely because the design was evolving so significantly through testing and trials. Andrea Perdomo says, “We asked Dynacast to do some expediting of tooling production, and other manufacturers might not have accommodated that. We’re a really small startup. Dynacast made sure we could get to market on time.”</p><p>In the end, the philosophy of design freedom embraced by Dynacast was a major advantage; not only to accommodate tight timelines, but also the flexibility of finishes that Revolar wanted, to make a device its customers would be pleased to make a habit of wearing.</p><p>“Our product is beautiful, it’s functional, and it’s affordable,” says Perdomo. “And it’s largely because of the Dynacast experience.”</p><p>If you are looking for a partnership to help you apply new tools and technologies, or help you fully realize your design vision, let us help you move your business forward, contact our team today to get the conversation started.</p>

Convert plastic parts to zinc die casting for enhanced strength, speed, and precision in manufacturing.

From Plastic to Zinc: Strength & Speed for Die Casting

Dynacast's collaboration with Revolar turned their vision for a sleek, high-quality safety device into reality, using zinc die casting to achieve the perfect balance of durability and aesthetic appeal

From Plastic to Zinc Die Casting

<h2>DOOR-IN-DOOR FEATURE FOR ENERGY-EFFICIENT REFRIGERATOR</h2><p>The average household refrigerator is opened 22 times per day. With each look inside, cold air escapes and warm air from the surrounding room circulates through. Once the doors are closed, the compressor must kick-in to re-cool the air and contents inside--impacting the owner’s energy bill and environmental footprint. But what if there was a way to access everyday items, such as drinks and snacks, without affecting the rest of the internal contents?</p><p></p><img asset_uid="bltd37d37ea0927e96f" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/bltd37d37ea0927e96f/670692c50d678426a923e75f/Picture17.png" alt="Picture17.png" height="auto"/><h2>INNOVATION THROUGH ALUMINUM DIE CASTING</h2><p>When the design team at a leading appliance manufacturer approached Dynacast to learn about die casting capabilities, they were unsure where and how they could benefit from the manufacturing process. The team at Dynacast Elgin was eager to help and offered an educational seminar to design engineers, outlining technical capabilities, material offerings, and overall benefits of die casting in the appliance industry. With a new design in mind, the engineers engaged Dynacast’s design for manufacturing (DFM) to find the best solution. Aluminum was very attractive to the team due to its lightweight properties and its high strength-to-weight ratio. Specifically, appliance engineers focused on decorative aluminum die casting for a new French-door refrigerator concept. The appliance would offer a door-in-door feature to allow the consumer access to popular items without opening the entire refrigerator and wasting cold air. By allowing the interior doors to stay closed and keep warm air out, the refrigerator would offer an innovative way to reduce energy consumption.</p><p></p><img asset_uid="blt871d3bf515f59c88" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt871d3bf515f59c88/670692c5a75c92f2970a2b62/Picture18.jpg" alt="Picture18.jpg" height="auto"/><h2>MAXIMIZING “SHELF LIFE”</h2><p>The appliance company’s marketing team was interested in offering a swinging “milk shelf” to allow easy access to the common household staple. Connection of the milk shelf to the interior body of the refrigerator would happen via a hinge component. In order to withstand the weight of a gallon of liquid, engineers determined the hinge would need to be stronger and more durable than plastic. The castability of zinc, its wear resistance, and structural integrity made it the ideal material choice.</p><p></p><img asset_uid="bltbcfda9c92a3fe4c1" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/bltbcfda9c92a3fe4c1/670692c5a75c9286890a2b64/Picture19.jpg" alt="Picture19.jpg" height="auto"/><p>In addition to offering functionality and stability, the shelf attachment needed to be decorative since it would be visible to consumers. Decorative aluminum die casting offered an eye-catching design and provided the rigidity and strength required. <strong>Dynacast Elgin designed and manufactured three parts in total: a decorative, aluminum die casted shelf and two, multi-slide zinc hinge components.</strong></p><h2>DYNACAST DELIVERS</h2><p>Dynacast strives to ensure every customer receives insight and expertise that adds value at every stage of the design and die cast manufacturing process. It’s why today, across multiple industries and multiple geographies, Dynacast is the name synonymous with precision-engineered metal components. <strong>Their extensive knowledge of metal die casting and reliable reputation made them a valuable partner for the appliance manufacturer.</strong></p>

Discover how aluminum die casting enhances energy efficiency while maintaining strength and performance.

Improve Energy Efficiency with Aluminum Die Casting

Dynacast helped a leading appliance manufacturer enhance energy efficiency in a new refrigerator design by utilizing aluminum die casting for a door-in-door feature, reducing cold air loss and lowering energy consumption.

Energy Efficiency Through Aluminum Die Casting

<h2>Eliminating Automotive Part Failure through DFM</h2><p>Many auto manufacturers have addressed the needs of their customers by installing locking fuel doors. As a frequently used component on a vehicle, it is critical that the lock itself doesn't fail so the driver can access the fuel tank and adds a level of security for the driver.</p><h3>Low-grade tooling and metal injection inconsistencies</h3><p>The fuel door lock manufacturer originally designed the part using aluminum. And once the design entered the first production run at the original foundry, they ran into inconsistent material shrinkage within the conventional tool. There were also problems filling the part—leaving inconsistencies from part-to-part and component failure. Due to poor material choices, as well as the lack of quality engineering, the part was destined to fail and lead the customer to seek out another solution.</p><p><strong>That’s where Dynacast comes in.</strong></p><p><strong></strong></p><img asset_uid="bltb893e56bb63e754e" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/bltb893e56bb63e754e/67067e174c601d11ff5186f3/Picture3.jpg" alt="Picture3.jpg" height="auto"/><h3>Die Casting vs. Machining</h3><p>It was clear that not only did the design need updating, but the process needed to be analyzed, as well. After reviewing different metalworking processes, the customer narrowed the decision down to machining and die casting. Although precision metal components are achievable through both production processes, the choice often comes down to efficiency and cost.</p><p>Dynacast’s multi-slide machines can be designed with multiple cavities and enable our engineers to cast extremely complex parts, quickly. A faster cycle time contributes to lowered overall cost per piece. Additionally, die cast tools ensure unmatched complexity of internal and external geometries, so there are fewer secondary operations associated with die casting. With the customer deciding on die casting, we were able to get started.</p><h3>Engineering expertise, software integration, and quality tooling</h3><p>The first step to eliminating the possibility for part failure was to find an engineering team that provides design for manufacturing (DFM) insight on the front end of the project. Dynacast engineers analyzed the design and used software to simulate the casting process, identify gating locations, and optimize the die for quality and longevity. And through the DFM process, our team of engineers identified Zamak 5, or zinc alloy 5, as the optimal casting metal. High strength and exceptional hardness made zinc the ideal alternative to aluminum.</p><p></p><img asset_uid="blt076f2e9917987f20" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt076f2e9917987f20/67067e1664332c657f8ebc3d/Picture4.jpg" alt="Picture4.jpg" height="auto"/><p>Dynacast engineering experts continued to uncover problems surrounding part failure. The original design presented poor material flow which directly affected the structural integrity of a part. With a well-planned tool design and a carefully controlled process, you can minimize part inconsistencies and achieve higher quality components. In this case, the Dynacast technical team was able to find the perfect gating solution for the part, as well as identify a 2-cavity tooling solution with an insert and interchangeable pins.</p><p>The quality tooling Dynacast was able to provide allowed for a much longer tool life that positively impacted the productivity level of the locking fuel door part. And with the large volumes, the customer needed a tool that would hold up over time and create quality components consistently. The multi-slide zinc tooling solution that Dynacast engineers provided the customer allowed for much more control and stability during production.</p><p></p><img asset_uid="blt9d2896fe3e0305c1" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt9d2896fe3e0305c1/67067e166c7a35754be3f3b9/Picture5.jpg" alt="Picture5.jpg" height="auto"/><h3>Satisfied customer</h3><p>Dynacast was able to provide the customer with the overall best solution. The ability to produce high-strength, precision components with quality tools, all while providing lower part prices in a timely manner, allowed Dynacast to secure the project and deliver valued parts.</p>

See how DFM strategies help eliminate part failure risks and improve reliability in automotive casting.

Prevent Automotive Part Failure with DFM

In design for manufacturing (DFM) and advanced die casting technology resolved automotive fuel door lock failures by replacing suboptimal aluminum with high-strength zinc alloy, optimizing tooling and production processes for enhanced quality, durability, and cost efficiency.

Eliminating Automotive Part Failure through DFM

<h2>DFM for Aluminum Die Castings</h2><p></p><img asset_uid="blt596e5a5461e932c4" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt596e5a5461e932c4/670680786c7d6c0473656063/Picture6.jpg" alt="Picture6.jpg" height="auto"/><p>When you think of an outdoor deck, the first thing you think of is probably wood. But what if there’s a better option? Something that won’t degrade, warp, rot or require regular annual maintenance? The innovators at Calgary-based SigmaDek knew there had to be a better way and approached Dynacast to help them find it.</p><h4>All the benefits, none of the drawbacks</h4><p>There’s nothing better than sitting in the sun on a gorgeous deck. Properly maintained, a deck is an extension of your living space and an asset to any property. But as any deck owner knows: they can be a lot of work. Year-in, year-out, wooden decks demand regular maintenance—from resurfacing to varnishing. And if they don’t get it, they can become dangerous eyesores.</p><p>Of course, until now, wood has always been the default material used for decks. But not any longer if SigmaDek has anything to do with it. We spent some time with Brian Boettger, VP Product Development to find out more.</p><h4>A collaboration of experts</h4><p>In order to achieve this dream, Brian said they recognized “we needed ‘best in class’ partners if we were to build the business to its full potential. We identified Dynacast as that partner and reached out to them very early on.”</p><h3>The advantages of aluminum</h3><p>However, in order to manufacture the precision components SigmaDek required, they needed die casting expertise which is when they turned to Dynacast. “Our expertise is not in die cast, so having the opportunity to work with the team at Dynacast was invaluable. They had a complete understanding of the process and its various idiosyncrasies to help in the fine-tuning of the design of each part,” said Brian.</p><h3>Rising to the challenge</h3><p>In order to deliver parts which provided the strength needed but did not add to the price, Dynacast’s engineers improved the design for manufacturability (DFM) for more than 30 unique die cast parts.</p><p>Changes included the elimination of undercuts, the addition of draft angles to some features, wall thicknesses, structural ribs, gates, runners, and overflows. By making the parts easier to die cast, the DFM modifications produced a significant cost benefit. Savings came in the form of less complex tooling, faster cycle times, and fewer secondary machining operations.</p><h3>Introducing a world first</h3><p>The result? The world’s first fully fabricated, non-wood decking system which meets all SigmaDek’s safety and maintenance goals.</p><p>Strong, sustainable and designed to enhance the beauty of any home, SigmaDek is the result of the finest minds in die casting and decking working together to achieve a world first. In the words of Brian Boettger, working together with Dynacast meant “we are able to deliver a product to the end-user which we are confident meets or exceeds anything else in the marketplace.”</p>

Explore how applying DFM to aluminum die castings ensures optimal performance and cost-effective results.

DFM for Aluminum Die Castings: Best Practices

DFM for Aluminum Die Castings

<h3>Design For Manufacturing Success</h3><p>Musculoskeletal disorders on the job cost employers $50 billion annually. But there are some jobs—even entire industries—in which machines just can’t perform as well as a highly trained, real-life person. Levitate Technologies set out to create a solution for professionals whose work requires constant shoulder mobility. In the process, and with the help of Dynacast, they ushered in the new age of worker safety and productivity: exoskeleton technology.</p><h4>Repeat Performance</h4><p>From automotive plants to manufacturing lines, millions of professionals work with their arms elevated, in a static position, or performing a repetitive motion for long periods of time.</p><p>To reduce fatigue and injury, companies provide ergonomic solutions like braces and stands; but until recently there has been no truly supportive solution for the shoulder joint. The consequences: skilled professionals who injure themselves or age out of a career too soon.</p><h4>Providing a Helping Hand</h4><p>“It’s a problem out there, and it’s a very costly problem,” says Joseph Zawaideh, VP of Marketing &amp; Business Development at Levitate Technologies. “Anything you can do to relieve fatigue, to reduce injury, to make workers happier is a welcome solution that manufacturers are very interested in exploring.”</p><p>It was that goal of reducing worker fatigue, physical burnout, and injury, while not intruding on the workspace that drove Levitate founder, President &amp; CEO, Mark Doyle to develop the innovative designs for what would become the AirframeTM. The Levitate team worked with the new production introduction team at Pathway NPI in San Diego, CA, to engineer and manufacture the technology.</p><h3>A Welcome Relief</h3><p>In his vision, a sleek, lightweight upper body exoskeleton could transfer part of the weight of the arm off of the wearer’s shoulder, neck, and upper back and disperse it safely to the core body—greatly reducing the risk of injury and muscle weakness.</p><p>To accomplish this and keep the wearer’s workspace clear of obstructions, the exoskeleton would need to utilize the most precise ergonomic technology, and be made as light and convenient to wear as possible.</p><p>Importantly, the AirframeTM would have to be manufacturable in quantities that companies around the globe could procure to protect and enable their employees. This critical factor narrowed the field of outsource manufacturers that Levitate could engage, and Mark went to great lengths to find the right one to choose for a partner.</p><p>“They had to be the best of the best,” says Mark, “because we’re going to be making tens of thousands of these devices. Workers around the world are going to be applying pressure on them all day long. Only a company like Dynacast can really provide that level of precision with that level of load management.”</p><h3>Design for Manufacturability</h3><p>Dynacast’s engineers helped ensure the quality, rigidity, and performance of Levitate’s new exoskeleton technology through a series of comprehensive design for manufacturability (DFM) sessions over several months.</p><p>“Before Dynacast, Levitate had not done any of the design for manufacturability work. In fact, all of DFM was driven by Dynacast,” says Mark.</p><p>This was crucial, specifically because the shoulders of the Airframe™ include cassettes filled with tiny components that essentially drive the device and disperse the weight to the core body.</p><p>“The components have to be very rigid and withstand the load, but they also have to be ultralight at the same time. It’s almost like a surgical instrument level of accuracy, but body worn,” says Joseph.</p><p>Dynacast’s engineers solved tricky tolerance, width, and size issues and ultimately specified die cast processes, both for the zinc parts—making them exceedingly durable—and for aluminum, making it incredibly lightweight.</p><h3>Removing the Burden</h3><p>“The final prototype that Dynacast helped us build is in the hands of real users wearing it in real plants,” says Joseph. And the feedback from global companies working with those prototypes? “’We want to order more.’”</p><p>Exoskeleton technology is on the rise as more companies realize its potential as a solution to worker safety, opening Levitate up to new competition. But, thanks to its patented designs and Dynacast’s commitment to its development, it can be manufactured three times lighter than any other exoskeleton currently in production.</p><p>“We engineer solutions. We always want to get involved very early-on with a program so we can engineer the best components and be part of the solution.” – Dan Taylor, Dynacast</p>

Learn how design for manufacturing (DFM) principles improve part quality, efficiency, and cost control.

Design for Manufacturing: How to Ensure Success

Design for Manufacturing Success

<h1>Get your free copy of “Which metal is right for me?”</h1><p>A visual metal reference guide. All in one place.</p><p>Your at-a-glance guide to key metals and their properties for die casting.</p><p>Get your free copy of “Which metal is right for me?” by simply entering your details below.</p><p>Download your free copy of “<strong>Which metal is right for me?”</strong> to learn about: </p><ul><li>The ideal applications for our most popular manufacturing materials</li><li>The key characteristics for specifying your project</li><li>Which manufacturing process a metal is suited for</li><li>More than a dozen alloys, and why you would specify them</li></ul><p>And it’s all in a simple, at-a-glance guide. Enter your details to get instant access.</p><p>From the guide:</p><p><em>“The ‘castability’ of zinc, its wear resistance, and structural integrity make it perfect for the creation of the multi-faceted, highly complex shapes used in the automotive safety and electronics industry.”</em></p><h2>Download your copy to learn more.</h2><p></p>

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Compare die casting metals and discover the best option for your product's strength and performance.

Which Metal is Right for Your Die Casting Project?

Explore key metal properties, ideal applications, and alloy options for die casting—all in one convenient, at-a-glance reference. 

Which Metal Is Right For Me?

<h3>CNC Machining to Cost-Effective Die Casting</h3><p>Realizing most people were turning to their cell phones for always-on photography, Light set out to develop a new type of camera. One that combined the convenience and portability of a cell phone with the high image quality of a DSLR rig.</p><p>To make this groundbreaking and highly precise technology perfect, they knew there was only one manufacturing process that could meet their extraordinarily tight spec—and that only Dynacast could build it.</p><h4>Today, everyone is a photographer</h4><p>You see it everywhere: people of all levels of skill and enthusiasm, snapping images with their smartphones at the instant something interesting happens, and then publishing them to the world within the moment.</p><p>But those images aren’t the best quality, given the optics and the processing limitations of our smartphones—consumer devices that are pressed into service for so many tasks that photographic imaging is not a priority for manufacturers.</p><p>On the other hand, having an easy-to-use camera always ready gives the smartphone size and shape a distinct advantage. DSLR cameras are cumbersome and difficult to have at the ready for that impromptu moment of photo magic.</p><h4>Convenience meets quality</h4><p>The innovators at Light saw that smartphones were just not good enough for people who want to capture emotional, never-to-be-duplicated life moments with the professional quality that a DSLR could.</p><p>Their invention, the Light L16 Camera, employs 16 internal camera modules of multiple focal lengths simultaneously—letting in maximum light—then sews the images together computationally for a high-quality finished photo with nearly infinite depth-of-field control. All in a chassis the size of a cell phone.</p><p>So that chassis had to be perfect.</p><h4>Shedding light on the challenge</h4><p>Setting out, Light knew they needed the chassis to be kept as small as possible, and required a cost-effective option for a go-to-market product.</p><p>As work began, it became clear just how difficult it was going to be to build the product with such small dimensions, given the varying sizes of the internal components.</p><p>One very simple, but cost-prohibitive, alternative kept coming up—CNC machining. The problem? CNC machining the part costs five times more than die casting. Calling on past experience with Dynacast, Jennifer Hochstatter, VP of Operations at Light, knew they could help.</p><p>“Let there be no mistake: it was very challenging on Dynacast’s side to make this happen. We were demanding of die casting. They were up for the challenge, taking a risk on a small, unproven company, and they made it work,” says Jennifer.</p><h4>Seeing the process through</h4><p>The biggest hurdle during this project was creating the die cast part—at the size required—so that it could be duplicated on a scale of mass production.</p><p>That’s where Dynacast’s expertise came in—handling very tight tolerances and making very thin and small wall sections that are manufacturable on a large scale.</p><p>“This camera is really pushing the boundaries of what die casting is capable of. That’s why we required Dynacast’s help, in being able to accept those incredibly tight tolerances and really demanding specifications,” says Jennifer.</p><p>Secondly, with the incredibly complicated internal optics—mirrors bouncing light into sensors in tightly calibrated conditions—it was vital that the technique Dynacast used to finish the interior surface allowed for no reflection whatsoever. Likewise, the external surface required cosmetic painting to create an attractive consumer look rather than an industrial-looking fabrication.</p><p>“That processing also isn’t easy to get just right,” according to Jennifer. “That’s something else Dynacast could do, their ability to paint on an anodization. The type of aluminum material we’re using is very unique, and they’re one of the only ones in the world that can do it.”</p><h3>Investing in innovation</h3><p>“Having Dynacast be a part of this project, they’ve proven themselves to be a true partner, willing to buy into the dream that this camera is going to be a game-changing innovation,” says Jennifer.</p><p>Thanks to their strong commitment to collaboration, Dynacast was able to develop the ideal solution. Light has made their multi-aperture computational camera a reality, without having to compromise on camera size, manufacturing cost, or overall aesthetic design.</p><p>If you are looking for a partnership to help you apply new tools and technologies, or help you fully realize your design vision, let us help you move your business forward, contact our team today to get the conversation started.</p>

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See how switching from CNC machining to die casting can reduce costs and improve production efficiency.

From CNC Machining to Cost-Effective Die Casting

CNC Machining to Cost-Effective Die Casting

<h1>Get your free copy of our Die Casting Design Guide</h1><p>Your biggest component production costs shouldn’t go to waste.</p><p>Yet that’s what many secondary operations will result—in fact, up to 80% of a component’s cost can be attributed to secondary operations that can be made more efficient—or eliminated altogether.</p><p>Get your copy of Die Casting Design Guide. Simply enter your details below.</p><p>Download your free copy of our <strong>Die Casting Design Guide</strong> to learn:</p><ul><li>How to reduce weight on components</li><li>Why wall thickness adds to cost</li><li>What the best draft angle is for inside vs. outside surfaces</li><li>The one critically important factor frequently overlooked by designers</li></ul><p>And much more. Enter your details to get instant access.</p><p>From the guide:</p><p><em>“Design for manufacturing (DFM) is a core methodology that ensures your die cast parts perform to specification and require the minimum of secondary operations. This is important when you consider that these operations can often represent as much as 80% of the component cost.”</em></p><h3>Please fill out the form to access your copy of the white paper. </h3>

Explore design tips and key considerations for creating high-quality, efficient die cast parts.

Your Complete Die Casting Design Guide

Download your free copy of our Die Casting Design Guide to learn how to reduce component costs by minimizing secondary operations and optimizing design for manufacturing. 

Die Casting Design Guide

<h1>Get your free copy of Creativity Without Compromise</h1><p>Faster timelines. Tighter tolerances. Lower costs. And did we mention faster timelines?</p><p>If you’re running into these challenging conditions on your projects, you might be forced to make sacrifices that ultimately compromise your design. Fortunately, there are some key steps you can take to ensure your vision becomes reality.</p><p>Get your copy of <em>Creativity Without Compromise</em>. Simply enter your details below.</p><p><strong>Download your free copy of </strong><em><strong>Creativity Without Compromise</strong></em><strong>. In this free guide, you’ll learn:</strong></p><ul><li>When to engage your manufacturing partner</li><li>Which DFM factors improve quality and lower costs</li><li>Why staying up-to-date with latest manufacturing techniques really matters</li><li>How looking at the big picture pays off, every time</li></ul><p>And that’s just the start. Enter your details to get instant access.</p><p><strong>From the guide:</strong></p><p>“When timings become strained, the root of the problem often lies in the early stages of the process. By working concurrently with the DFM team, you can ensure this crucial process flows smoothly, saving you valuable time (not to mention stress).”</p><h2>Download your copy to learn more.</h2>

See how precision die casting allows for creative, complex designs without sacrificing performance.

Creativity Without Compromise in Die Casting

Discover how to achieve faster timelines, tighter tolerances, and lower costs without compromising your design in the free guide, Creativity Without Compromise.

Creativity Without Compromise

<h1>Get your free copy of Bulletproof Supply</h1><p>Don’t let manufacturing problems derail your project.</p><p>Our free ebook will help you spot some common supply chain risks so you can keep your projects on track.</p><p>Get your free copy of <em>Bulletproof Supply</em> by simply entering your details below.</p><p><strong>Download your free copy of Bulletproof Supply to learn about:</strong></p><ul><li>The three major areas of risk with outsourced manufacturing</li><li>Less-obvious ways manufacturing issues can affect your operations</li><li>The 7 risk mitigation angles required in today’s supply chain</li><li>The surprising way redundancy can eliminate points of failure</li></ul><p>And everything else you need to look out for. Enter your details to get instant access.</p><p><strong>From the guide:</strong></p><p>“The impact of lack of preparedness for any of the risk factors – whether surrounding location, business practice, or robustness – can fall anywhere from barely noticed (if it doesn’t affect your project timeline) to white-knuckle investor calls—or worse.”</p><h3>Please fill out the form to access your copy of the white paper.</h3>

Learn how die casting strategies help build resilient, reliable supply chains across industries.

Achieve Supply Chain Resilience with Die Casting

Download our free ebook Bulletproof Supply to discover key strategies for identifying and mitigating supply chain risks, ensuring your manufacturing projects stay on track.

Bulletproof Supply

<h2>Power of Precision </h2><p>Are you new to precision die casting or a veteran with years of expertise? And staying ahead of the game when it comes to precision die casting is critical. With die casting, you can create complex net-shapes, including complex internal and external features with minimal draft angles-minimizing secondary operations. <br /> <br />Join us as the Dynacast Europe team presents Precision in Production: Die Casting Capabilities. In this webinar, our team will cover: </p><ul><li>Die casting technologies</li><li>Material options</li><li>Design capabilities</li><li>Case studies</li><li>And more!</li></ul><p><strong>Precision in Production: Die Casting Capabilities</strong><br /><strong>When: On-Demand</strong></p><p><strong>** Note this webinar is presented in English.**</strong></p><h2>Fill out the form to watch our free webinar on-demand.</h2>

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Understand how precision die casting delivers complex geometries, tight tolerances, and superior quality.

Precision in Production: Die Casting Capabilities

Bernd Froehlich

Sergio Perino

Christian Flich

Discover the cutting-edge die casting technologies, material options, and design capabilities in 'Precision in Production: Die Casting Capabilities 

Precision in Production Die Casting Capabilities

<h1>Overcome Die Casting Defects</h1><p><strong>Join our exclusive webinar on advanced techniques and solutions. </strong></p><p><br />Struggling with die casting defects that impact your production efficiency and product quality? Looking for expert guidance to optimize your die casting processes? <br />Join our highly informative and engaging webinar, "Overcome Die Casting Defects." Gain the knowledge and techniques to identify, prevent, and resolve common die casting defects. </p><p>Why Attend? </p><ul><li>In-Depth Knowledge: Defects, causes, troubleshooting. </li><li> Advanced Techniques: Minimize defects, optimize parameters. </li><li>Interact with Experts: Engage directly with our panel of die casting experts.  </li><li>Drive Efficiency and Savings: Improve efficiency, achieve cost savings. </li></ul><p><strong>Webinar Details: </strong></p><ul><li><strong>Overcome Die Casting Defects </strong></li><li><strong>When: </strong>On-Demand<br /></li></ul><p>Who Should Attend? Ideal for die casting engineers, manufacturing managers, quality control personnel, and professionals involved in die casting. Valuable insights and practical solutions for beginners and experts alike. <br /> <br />Secure Your Spot Now! </p>

Explore common die casting defects and discover practical solutions to improve product quality.

How to Overcome Common Die Casting Defects

Rodrigo Ballesteros

Sr. Business Development Manager

Max Gondek

Sr. Applications Engineer

Explore advanced techniques and expert strategies for identifying, preventing, and resolving die casting issues, enhancing production efficiency and product quality. 

Overcome Die Casting Defects

<p>Are you facing challenges with your die casting tooling? Whether it's supplier issues, the need for onshoring, or simply optimizing your production, transferring tooling can be complex. Join our free webinar, "Smooth Transitions: Mastering Die Cast Tooling Transfers," to learn how we simplify this process for you.</p><p><strong>In this webinar, you'll discover:</strong>&nbsp;</p><ul><li><p>How to streamline your die cast tooling transfers for maximum efficiency.&nbsp;</p></li></ul><ul><li><p>Strategies for successful onshoring and consolidation of your die casting operations.&nbsp;</p></li></ul><ul><li><p>Best practices for risk mitigation and ensuring supply chain security.&nbsp;</p></li></ul><ul><li><p>Real-world case studies showcasing successful tooling transfers.&nbsp;</p></li></ul><p><strong>Featured Case Studies:</strong>&nbsp;</p><ul><li><p><strong>Safety-Critical Transfers:</strong> Learn how we helped a leader in safety-critical components seamlessly transfer numerous tools while maintaining impeccable quality and reliability.</p></li></ul><ul><li><p><strong>Rapid Response and Onshoring:</strong> Discover how we enabled a solar mounting company to rapidly onshore production to meet surging demand and take advantage of federal incentives.</p></li></ul><ul><li><p><strong>Consolidating Production:</strong> See how we helped a major lock manufacturer consolidate a large number of tools from their in-house operations, preventing potential disruptions and ensuring a smooth transition.</p></li></ul><p><strong>Why Attend?</strong>&nbsp;</p><p>Transferring die cast tooling can be a daunting task, but with the right partner, it can be a smooth and efficient process. This webinar will provide you with the knowledge and insights you need to make informed decisions and avoid costly mistakes. We'll share our proven methodologies, best practices, and real-world examples to help you achieve your production goals.&nbsp;</p><p><strong>Webinar Details:</strong>&nbsp;</p><ul><li><p><strong>Date:</strong> May 1, 2025&nbsp;(previously April 17, 2025)</p></li></ul><ul><li><p><strong>Time:</strong> 2pm EST&nbsp;</p></li></ul><p><strong>Who Should Attend?</strong>&nbsp;</p><p>This webinar is ideal for manufacturing engineers, purchasing managers, supply chain professionals, sourcing.</p><p></p><p></p>

Learn best practices for managing die cast tooling transfers and ensuring production continuity.

Die Cast Tooling Transfers Guide | Dynacast

Are you facing challenges with your die casting tooling? Whether it's supplier issues, the need for onshoring, or simply optimizing your production, transferring tooling can be complex. Join our free webinar.

Smooth Transitions: Mastering Die Cast Tooling Transfers

<h1>Innovations in Precision Die Casting</h1><p>Casting may be one of the oldest forms of metal manufacturing, but the techniques being utilized today are far from old-fashioned. In fact, they are continuously being developed and improved.</p><p>Download our online seminar where we will discuss the most recent innovations in precision die casting. In this seminar, you will learn about the advanced technologies Dynacast uses to manufacture more than 5 billion components annually for customers across almost every industry.</p><p>We'll cover:</p><ul><li><strong>Advanced casting machines and techniques</strong></li><li><strong>Tooling and engineering expertise with customer case studies</strong></li><li><strong>Custom alloys</strong></li><li><strong>Cosmetic plating and coating</strong></li><li><strong>And more!</strong></li></ul><p><strong>Fill out the form to download the webinar.</strong></p><p></p>

Explore new technologies and innovations shaping the future of precision die casting techniques.

Precision Die Casting Innovations | Dynacast

Discover the latest advancements in precision die casting, including cutting-edge machines, innovative tooling techniques, custom alloys, and more, in our informative webinar by Dynacast. 

Innovations in Precision Die Casting

<h1>Tool Quality, Tool Maintenance, and Tool Replacement</h1><p>When it comes to being a successful manufacturer, you want to get the most value out of each step of your production process, and it can be tempting to cut corners. Without knowing much about the importance of tooling, some manufacturers can slip into the trap of cutting cost with cheaper molds.</p><p>Great tool design is critical to the overall success of your project. No matter how advanced your die cast machines are, if you cut costs for a cheaper tool, you run the risk of creating mediocre parts, adding costs with unnecessary secondary operations—or worse, complete project failure.</p><p>Sign up for our free on-demand webinar and learn about the importance of quality tooling to see the most ROI on your project, how to properly maintain a tool, and when it’s necessary to replace your die cast mold. In this webinar, we’ll cover</p><ul><li>What makes a quality tool</li><li>Dynacast tool maintenance standards</li><li>Designing to prolong the life of your tool</li><li>And more!</li></ul><p><strong>Fill out the form to sign up for our free on-demand webinar.</strong></p><p></p><p></p>

Discover how to maintain, replace, and ensure the quality of die casting tools for optimal performance.

Die Casting Tools: Quality and Maintenance Tips

Discover how Design for Manufacturing (DFM) can streamline your design process, reduce component costs, and enhance tool longevity in our on-demand webinar, where we'll explore core DFM concepts, inefficiency elimination, and the benefits of early engineer involvement. 

Die Casting Tools: Quality, Maintenance, Replacement

<h2>Higher quality and cost savings with die casting</h2><p>The die casting process is ideal for producing extremely complex components at high volumes. While other manufacturing processes like machining, stamping, or spin casting may offer quality or volume, die casting delivers both. How?</p><p>The key lies in world-class process controls and superior automation.</p><p>We’ve covered the foundations of die casting technologies, and now we want to showcase our state-of-the-art processes and automation in real time. With advanced automation, Dynacast delivers reliability, cost savings, and improved part performance.</p><p>Discover how our automation reduces risk, cuts costs, and accelerates production by watching our on-demand webinar, featuring videos of our technology in action. In this webinar, we cover:</p><ul><li>Automated die casting processes</li><li>How automation removes added costs and risk</li><li>How automation speeds up component delivery</li><li>And more!</li></ul><p>Fill out the form to access our free on-demand webinar.</p><p><strong>For the best experience, please use Google Chrome, Safari, or Firefox. This webinar will be presented in English.</strong></p><p></p>

See die casting technologies in action with this engaging virtual demonstration of key processes.

Die Casting Technologies Virtual Demo

Join this webinar showcasing how advanced automation in die casting enhances quality, reduces costs, mitigates risks, and accelerates production through real-time demonstrations of cutting-edge processes. 

Die Casting Technologies in Action: Virtual Demonstration

<p>When it’s time to choose materials for your die cast component design, how will you decide which metal to use?</p><p>Before you go too far in your design, it helps to learn a bit about each of the options readily available for manufacture. Download our on-demand seminar to learn from our metals expert about <strong>Die Cast Material Options </strong>to give you a top-level view of the choices you’ll need to make, including a full list of alloys and our free interactive process and metal selector.</p><p>Fill out the form to access our free webinar! </p>

Understand die casting materials and learn how to select the best option for your application needs.

Choosing the Right Die Casting Materials

Learn about various die casting material options and get expert insights to help you choose the right metal for your component design in this on-demand seminar. 

Die Casting Materials

<p>Want to hear from some of the best design engineers within the die casting industry? Download our Die Cast Design Roundtable and hear from our multi award-winning engineering team!</p><p>Learn more about designing the best part possible with our unique design for manufacturing approach and hear first-hand how we won not one but two NADCA design awards last year! PLUS see this year's award winning design.</p>

Get expert insights on die casting design challenges and practical solutions for complex projects.

Insights from the Die Cast Design Roundtable

Access our on-demand Die Cast Design Roundtable to hear insights from award-winning design engineers on creating optimal die castings, including a showcase of this year's award-winning design. 

Die Cast Design Roundtable

<h2>Design engineering is changing and it’s changing fast.</h2><p>Today’s engineers are under a lot of pressure to get a viable component quickly and more efficiently than ever before. And Design for Manufacturing (DFM) discussions with your supplier are one of the best practices engineers follow to ensure proof of concept, part optimization, and scalability.</p><p>Outlining a successful plan and process for your part is just as important as the component itself. The design is crucial to the entire production process—and impacts everything from material cost to time-to-market.</p><p>In this webinar, <strong>Design for Manufacturing: A critical step for successful production, </strong>Dynacast’s Senior Application Engineer, Max Gondek, discusses the benefits of working with an engineer early in the design phase of your die cast part. He covers:</p><ul><li>How to reduce weight on components</li><li>Why wall thickness adds to cost</li><li>What the best draft angle is for your part</li><li>How to strengthen your casting with fillets and radii</li><li>And many more design tips!</li></ul><h2>Fill out the form to sign up for our free webinar.</h2><p></p>

Learn how design for manufacturing (DFM) boosts quality and efficiency in die casting production.

DFM: Key to Successful Die Casting Production

In this on-demand webinar, Dynacast’s Senior Application Engineer, Max Gondek, reveals essential Design for Manufacturing (DFM) strategies to optimize component design, reduce costs, and improve production efficiency through early collaboration with engineers. 

DFM: A Critical Step for Successful Production

<h2>Three innovative technologies that deliver solutions</h2><p>The die casting process can have significant advantages over other manufacturing processes. With die casting, you can cast net-shape components to minimize secondary operations and consolidate multiple parts into a single component, allowing you to:</p><ul><li>Eliminate unnecessary assembly operations</li><li>Streamline your supply chain</li><li>Simplify stock control</li><li>All while gaining greater performance and part-to-part consistency</li></ul><p>But what technologies make that possible?</p><p>Dynacast is home to three innovative technologies that solve common manufacturing problems: <strong>multi-slide die casting, injected metal assembly, and center gate technology.</strong> Struggling with consistent part quality at high volume? Multi-slide die casting could be the solution for you. Looking for a better, longer-lasting assembly method for similar or dissimilar materials? Look no further than injected metal assembly. Have a component that needs complex external threads? Learn more about our center gating technology.</p><p>Submit your information below for access to our free webinar on "Three Technologies that Solve Common Manufacturing Problems." In this webinar, our presenters discuss how die casting answers the call when other processes fail to deliver solutions.</p><h2>Fill out the form to sign up for our free webinar.</h2><p></p>

Uncover three key technologies that resolve common manufacturing issues in design, production, and assembly.

How To Solve Manufacturing Issues | Dynacast

Discover how Dynacast's multi-slide die casting, injected metal assembly, and center gate technology address common manufacturing challenges and enhance efficiency in our free webinar. 

Three Technologies that Solve Common Manufacturing Problems

<h2>Sustainable Die Casting for a Better Environment</h2><p>At Dynacast, we recognize the challenges organizations face as they shift towards sustainability. We understand the complexities involved in this transformation especially for manufacturing. That is why we are adapting to meet the growing demand for sustainable die casting solutions.<br />Our commitment to sustainability is exemplified by our efforts in recycled zinc and aluminum die casting, plant process improvements, and environmental commitments. We are not just embracing the change; we are casting the way. <br /> <br />Join us as the Dynacast Europe team explores the future of sustainable die casting. Discover how sustainable practices can reshape precision die casting:</p><ul><li>Eco-friendly partnerships in die casting: Understand the importance of partnering with environmentally conscious companies meeting the demands of companies looking to achieve sustainability goals for 2030 and beyond.</li><li>Renewable energy: Learn how our solar panel implementation reduces our carbon footprint and dependence on fossil fuels.</li><li>Metal recycling: See how we recycle aluminum and zinc, reducing energy consumption and waste generation.</li><li>Case studies in sustainable die cast part solutions </li><li>And more!</li></ul><p><strong>Sustainable Die Casting for a Better Environment </strong><br /><strong>When: On-Demand</strong></p><h2>Fill out the form to watch our free webinar on-demand.</h2>

See how sustainable die casting practices can lower emissions, reduce waste, and contribute to a greener future.

Sustainable Die Casting | Dynacast

Vice President of Sales

Roman Hartl

Business Development Manager

Mathew Wallace

FP&A Manager

Discover how Dynacast is pioneering sustainable die casting with eco-friendly practices, renewable energy, and metal recycling to reshape the future of precision manufacturing in our on-demand webinar. 

Sustainable Die Casting for a Better Environment

<p>Download our free webinar, Surface Finish 101 to discover insights on many different casting finishes. From utility and functional grade to commercial and consumer grade coatings—including decorative finishes—we will walk you through the considerations you should be making before selecting a surface finish as well as tips for process control.</p><p>Fill out the form to access our free webinar! </p>

Learn about the importance of surface finish in die casting and how it affects aesthetics, performance, and durability.

Die Casting Surface Finish Basics | Dynacast

Explore the essential insights on various casting finishes—from functional to decorative—by downloading our free on-demand webinar, Surface Finish 101. 

Surface Finish 101

<p>We understand that customers are under more pressure than ever to redesign components that keep up with rapidly changing technology and sustainability regulations. Many customers go about this by retrofitting past designs because it is the quickest and easiest way to production.</p><p>However, what customers fail to realize is even though their materials and designs may meet regulations and pass testing, there are more advanced and efficient options for manufacturing.</p><p>Register for this webinar to learn how die casting lends itself to solving some of the biggest challenges in manufacturing today. Also, we cover solutions for the following trends:</p><ul><li>Evolving technologies</li><li>Demand for skilled workers</li><li>Rising raw material price</li><li>Sustainability efforts</li><li>Changing regulations</li><li>And more!</li></ul><p><strong>Fill out the form to sign up for our free on-demand webinar.</strong></p>

Explore manufacturing solutions that address evolving market demands, material costs, and supply chain resilience.

Solutions for Market Challenges | Dynacast

Discover how die casting can help you navigate evolving technologies, sustainability efforts, rising costs, and other key manufacturing challenges. 

Manufacturing Solutions for Evolving Market Challenges

<p>Looking for a manufacturing solution that can join two or more dissimilar components together? Our injected metal assembly (IMA) process is a method that provides a permanent reliable bond by injecting a small amount of molten zinc around the components being joined.</p><p><strong>Learn more about IMA by downloading our webinar!</strong></p><p>We’ll cover:</p><ul><li>The IMA process</li><li>The advantages of utilizing this innovative bonding method</li><li>Materials you can join using the IMA process</li><li>Applications and solutions for a variety of industries</li></ul><p><strong>Fill out the form to access the webinar! </strong></p>

Learn about Injected Metal Assembly (IMA), how it works, and how it improves part strength, precision, and speed.

What Is Injected Metal Assembly? | Dynacast

See how our Injected Metal Assembly (IMA) process creates a permanent, reliable bond by injecting molten zinc around dissimilar components—perfect for a wide range of industries. 

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