The CWM Die Casting Design and Specification Guide for Custom Al, Mg & Zn Components

A Condensed Resource for OEM Designers and Engineers Comprehensive guidelines for cost- effective die casting production. Written for OEM product designers and engineers to aid in optimizing their part designs and specifications for custom production in Aluminum, Magnesium, and Zinc die casting alloys.

Prepared and updated by

® Chicago White Metal Casting, Inc. Bensenville, Illinois U.S.A. CONTENTS Page Browse CWM’s DC2

Design & Specification Guide Introduction 3 (Die Cast Design Center)

Recyclability&EnvironmentalPractices 3 Over 70 die casting design guides & bulletins AnatomyofaDieSet&DieCastPart 4 are available to OEM DESIGN & SPECDECISIONSTEPS product designers and 1 MatchingMaterialProperties 5 engineers for download 2 Die&UnitDieConstruction 6 24/7 at our website:

CastFeatures&DieElements 6 http://dc2.cwmdiecast.com AssuringLongerDieLife 7 CWMProduction&DieLIfe,byAlloy 7 3 MinimizingPartPorosity 8 4 OptimizingPartHeatTransfer 8 5 PreplanningPost-CastingMachining 8 6 TolerancingGuidelines:Caution 9 7 MetalExtension(Flash)Guidelines 10 8 As-CastFinishGuidelines 10 9 FurtherComponentDesignAssistance 11 10 Magmasoft® DieFlowSimulation 12 11 PrototypingforDieCasting 12

FusedDepositionModeling(FDM) 12 MachinedPrototypes 12 12 Post-CastingOperations 13

CNCPrecisionMachining 13 SurfaceTreatmentsandFinishing 13 13 CWMCollaborativeEngineering 14

Customer-CWMInteraction 14 TheCollaborativeEngineeringModel 14 CustomerResponsibilities 15 14 DesignFileTransferOptions 15 15 ContractManufacturing&Assembly 15 CWM Design & Specification Resources 16

Design Information by Instant Download 16 Disclaimer CWMSales/Engineers 16 Every effort has been made to assure the accu- Website&ContactInformation 16 racy of the data presented in this Design and Specification Guide, but Chicago White Metal Casting cannot be responsible for results obtained with this data. CWM disclaims any liability arising out of the use of this material. No warranties, express or implied, are given in connection with this publication.

2 CWM Design and Specification Guide Design & Specification Guide Introduction The guidelines presented in this publication are intended to aid OEM product design engineers in designing and specifying parts for cost-effective die casting production—in aluminum, magnesium, zinc and ZA-8 alloys. They were researched and compiled by Chicago White Metal Casting from its over 70 years of industry experience and the latest design and production resource data, relying primarily on NADCA Product Specification Standards for Die Casting. These design-for-die casting guidelines are intended as a concise and easily referenced initial source for the key specification characteristics that drive the cost and performance of components die cast in Al, Mg and Zn alloys. Many of the Standards and Guidelines presented require further detailed qualifications, dependent on the specific design, configuration and performance requirements of a proposed part. In such cases, the detailed NADCA Standards and other sources are referenced. Note that the CWM engineering department should always be consulted early in the product concept stage, before irrevocable design-for-manufacturing decisions are made. Selected design data, including sections of the NADCA Product Specification Standards manual, are available by instant download in Adobe PDF Reader format from the CWM website’s OEM Resource Center, in the Engineering Bulletins section, at www.cwmdiecast.com. This valuable reference volume can also be purchased from CWM at a special discount, using the special discount order form in the Resource Center’s Reference Manuals section. Recyclable Die Castings and Environmental Practices All of the metal alloys used by CWM are produced from recycled raw materials. All of SPECIFICATION Steel Mill the aluminum parts, for example, are die & Others ALLOY cast from post-consumer recycled alu- INGOT minum, which has the capability of repeatedly meeting the requirements of high-performance applications. Dross The die casting alloy recycling stream, illus- SECONDARY SMELTER DIE AND and CASTER trated here, is based on the existing worldwide PRIMARY PRODUCER Fines infrastructure that has been operative for over 60 years. This basic pattern, with varying Al, Mg, amounts of reclaimed alloy going to sec- Zn Internal Finished Reclaim Die ondary and primary producers, applies to Other Reclaim Castings Nonferrous the majority of all metal cast into compo- Reclaim nents by Chicago White Metal Casting. Ferrous Plastic and and other The environmental management systems of Nonferrous "Fluﬀ" END-PRODUCT CWM and its division’s are ISO 14001 registered. Reclaim MANUFACTURER

The company is a charter member of the U.S. Component EPA’s Environmental Performance Track Program Remanufacture RECLAIM and and has been named by the EPA as a Green Biz SEPARATION Servicing FOR Final Leader company. Assembled RECYCLING Products

End of Product END Fig. 1 Life USER

CWM Design and Specification Guide 3 Anatomy of a CWM Die Set and Die Cast Part Premium tool steel, used Precision shut-offs, to build all CWM die cavi- part of advanced runner Special surface treatment ties, assures maximum die Automatic moveable slides and overflow design, help is used on all CWM die life and machine perfor- can produce all holes minimize any porosity in Oil heating & cooling lines cavities to help prevent mance. Magmasoft®metal- and features as-cast. the final cast part . are used in both halves of premature die wear. flow simulation & thermal The ejector half of this the die set for precise analysis of a design prior die casting die set temperature control dur- to die build helps assure is at left. ing very rapid casting first shot success. cycles. The cover, or sta- tionary, half is at right.

Heat sink fins can be die cast in place to maximize the surface area and Natural thermal conductivity achieve optimal heat of a die cast housing, com- transfer where required. bined with an as-cast heat sink, can eliminate the need for fans in electronic parts. Cosmetic surface finishes can be produced as-cast with special attention to die design, construction and process control. Built-in EMI shielding is provided by a die cast housing as a permanent intricate features, cored holes Thin, rigid walls can be die integral feature of the and bosses can be cast cast to minimize package cast component. in place—including logotypes size—an advantage or other designations, and Recyclable Al, Mg & Zn matched by no other high- even external threads—often die casting alloys are speed production process. eliminating all machining. offered by CWM, certified free of impurities.

4 CWM Design and Specification Guide KEYDESIGNDECISIONSTEPS MATERIALPROPERTIES&NOMINALCHEMISTRY

Table 1 Typical Material Properties: Die Casting Alloys & Selected Plastics 1 Matching Material Properties Typical alloy values based on “as-cast” characteristics for separately die cast specimens, not specimens cut from production die castings. (2006 NADCA Standards. Sec. 3) Die casting materials are precisely formulated metal alloys which offer the mechanical properties Die Casting Alloys Thermoplastics of medium-strength metals. They are generally Commercial: Al 380 Mg Zn 3 ZA-8 Lexan® Torlon® several times as strong and many times more AZ91D rigid than plastics, and their mechanical proper- ANSI/AA: 380.0 AG-40A 3413 4203L ties compare favorably with powdered iron, MECHANICALPROPERTIES brass, and screw-machined steel. Ultimate Tensile Designing for proper strength in a product ksi 46 34 41 54 19 27.8 depends on two main factors: strength of the (MPa) (320) (230) (283) (372) (130) material selected and configuration of the part. Yield StrengthᎭ Die casting alloys offer a wide range of as-cast ksi 23 23 32 41-43 -- -- (MPa) (160) (160) (221) (283-296) material strengths, ranging as high as 54 ksi (372 MPa) ultimate tensile. The designer can usually Elongation % in 2 in. (51 mm) 3.5 3 10 6-10 3-5൷ 15 develop sufficient strength in critical features sim- HardnessᎮ ply by providing adequate wall thickness. Where BHN 80 75 82 100-106 -- -- additional strength is required, reinforcing features Shear Strength such as ribs, flanges and locally thickened sec- ksi 28 20 31 40 10.5 18.5 tions can be accurately computed and precisely (MPa) (190) (140) (214) (275) (72) cast. (See Guidelines G-6-2-2006 and G-6-3- Impact Strength 2006 in NADCA Standards.) ft-lb 3 1.6 43൵ 24-35൴ 2൸ -- The die casting process allows the product (J) (4) (2.2) (58) (32-48) (100) designer freedom to create extremely intricate Fatigue StrengthᎯ ksi 20 10 6.9 15 6൹ -- contours, varying the wall thicknesses over vari- (MPa) (140) (70) (47.6) (103) (40) ous sectors of the product. Where strength Young’s Modulus requirements are not critical, CWM high-tech die psi x 106 10.3 6.5 ൶ 12.4 1.25 0.7 casting can produce rigid components with ultra- (GPa) (71) (45) (85.5) (8.6) thin walls. As a result, the designer has much PHYSICALPROPERTIES more latitude with die casting than with plastics, Density powdered metals, or stampings to design rela- lb/in3 0.099 0.066 0.24 0.227 0.052 0.050 tively thick walls for strength in some areas, and (g/cm3) (2.74) (1.81) (6.6) (6.3) (1.43) (1.38) very thin walls for conserving material in others. Melting Range CWM offers the designer material choices in all °F 1000-1100 875-1105 718-728 707-759 -- -- of the major non-ferrous alloy categories: alu- (°C) (540-595) (470-595) (381-387) (375-404) minum, magnesium and zinc. Specific Heat BTU/lb°F 0.230 0.25 0.10 0.104 0.27 -- Aluminum 380 Alloy (J/kg°C) (963) (1050) (419) (435) Die casting alloy Al 380 is the most widely used of Coefficient of Thermal Expansion the aluminum die casting alloys, offering the best µ in./in./°F x 10-6 12.2 13.8 15.2 12.9 12.1 17 combination of properties and ease of produc- (µ m/m°K) (22.0) (25.0) (27.4) 23.2 (22) tion. It is specified for nearly every product type Thermal Conductivity where the properties of aluminum are desirable. BTU/ft hr °F 55.6 41.8Ꭿ 65.3 66.3 150ൺ 1.77 All aluminum die casting machines operate by the (W/m°K) (96.2) (72) (113) (115) (0.21) cold-chamber production process. Electrical Conductivity Magnesium AZ91D Alloy % IACS 27 n/a 27.0 27.7 23 -- Electrical Resistivity൴ Magnesium is the lightest commonly used struc- 35.8 µ Ω in. n/a n/a n/a __ tural metal. Its use in die cast parts has grown (µ Ω cm) (14.1) -- dramatically, often replacing plastic parts with greater strength and rigidity at no weight penalty. Table 2 Nominal Chemical Composition: Die Casting Alloys Mg alloy AZ91D is the most widely-used mag- For detailed chemical composition, request appropriate CWM Instant Fax Line Document. nesium die casting alloy, offering high-purity with Nominal Comp: Cu 3.5 Al 9.0 Al 4.0 Al 8.4 excellent corrosion resistance, excellent strength Si 8.5 Zn 0.7 Mg 0.035 Mg 0.023 and excellent castability. Corrosion resistance in Mn 0.2 Cu 1.0

AZ91D is achieved by enforcing strict limits on With mechanical properties, note die casting alloys 380.0, A380.0, 383.0 and 384.0 are substantially metallic impurities. interchangeable. Ꭽ 0.2% offset Ꭾ 500 kg load, 10mm ball Ꭿ Rotary Bend 5 x 107/108 cycles Utilizing the faster cycling hot-chamber process ൳ Notched Charpy. ൴ AT 68°F (20°C) ൵ ASTM E 23 unnotched 0.25 in. die cast bar ൶ Varies with stress level; applicable only for short-duration loads. Use 107 as a first approximation. ൷ At rupture for its magnesium production, CWM operates ൸ Izod notched1/8” (3.2mm) ft.lb. (J/M) ൹ ASTM D671, 2.5mm cycles. ൺ Btu-in/h-ft2-°F

CWM Design and Specification Guide 5 two of among the world’s largest hot-chamber CWM unit dies are standardized unit die holders Mg machines. Its mag department is one of the into which replaceable die cavity “units” can be largest custom facilities in North America. inserted. These replaceable units can be removed from, or placed into, a unit die holder without Zinc (ZAMAK) No. 3 Alloy removing the unit frame from the die casting Zinc No. 3 offers the best combination of mech- machine. CWM unit dies can significantly reduce anical properties, castability, and economics die construction costs at smaller volumes. They among the zinc die casting alloys and is the most are available in single and double unit holders. widely used Zn alloy in North America. It can pro- The limitations of unit dies are that they gener- duce castings with intricate detail and excellent ally can only accommodate the production of surface finish at high production rates. In general, smaller-sized parts, and they restrict, or may elim- thinner sections can be die cast in zinc than in inate, the use of moving core slides. The configu- any other commonly used die casting alloy. ration of interchangeable unit die inserts, with the All zinc die castings are manufactured in hot- resulting limited die area for core slide functions, chamber die casting machines. makes unit dies most appropriate for less com- ZA-8 (Zinc-Aluminum) Alloy plex product designs. While any die casting die is a major investment, ZA-8, with a nominal aluminum content of 8.4%, the aggregate manufacturing cost of a compo- is the only ZA alloy that can be cast by the faster- nent, through final finishing and assembly, should cycling hot-chamber process. It has the highest be one of the key production decision criteria. The strength of any hot-chamber zinc alloy, and the elimination of secondary machining, cosmetic fin- highest creep strength of any zinc alloy. ZA-8 ishing and assembly operations can often cost- offers excellent bearing properties, with lighter justify more sophisticated die casting die designs. weight and greater strength than iron and bronze. It is being used by CWM to produce net-shape die cast parts to replace more costly machined Cast Features & Die Elements components The features that are required of a cast part deter- For a discussion of the hot- and cold-chamber mine the complexity of the die. The simpler the die casting processes, consult the Product part, the lower the cost of the die casting tool. Design for Die Casting manual, published by Castability and die cost will be greatly influ- NADCA and available from CWM at a discount. enced by the following: Are wall thicknesses as well as the ribs constant, or do they vary greatly? See Table 3a for approximate production part If bosses exist, do they vary widely in diameter? size and weight ranges, and machine tonnages, Will any thin channels on the design create thin offered by CWM for each alloy category. standing slivers of steel on the die? Is the part number and other engraving recessed into, rather 2 Die & Unit Die Construction than raised out of, the casting, making the die more difficult to machine? Are the cored holes The two die halves shown on page 4 are an that may be called for extremely small in diameter example of a single cavity die with both fixed and thus more difficult to cast? Fig. 2 A unit die set is cores and moving core slides which produce For the proper design of production tooling, illustrated below. Left to additional as-cast features in the part. The use of pressure tightness, secondary machining and sur- right, the (1) Unit Holder core slides can totally eliminate, or significantly face finishing specifications must be understood will contain either (2) a reduce, secondary machining requirements. Cavity Block, or (3) a Unit in detail. Areas of the casting subject to machin- Multiple-cavity dies can be used to increase Die. The Unit Die can con- ing must be fully discussed at the outset, so that tain (4) a removable production rates substantially; in some cases, the the die can be designed to reduce to an absolute Cavity Insert. use of multiple cavities may limit the use of certain minimum the presence of porosity in those areas. moving core slide operations. Cosmetic surface requirements for the casting will require special finishing of the cavities of the die. These are among the types of questions that the customer should be prepared to discuss at the earliest planning meetings. The NADCA Standards Manual provides detailed treatment of the tolerancing implications of various casting design features, as well as guidelines which apply under differing casting conditions. Moving Core Slide Options Fixed cores and core slides (or pulls) can be

NADCA designed into the die casting die to form selected

6 CWM Design and Specification Guide features, as cast, which otherwise would have to CWMPARTPRODUCTION&DIELIFE,BYALLOY be produced by additional machining of the die Table 3a Aluminum, Magnesium and Zinc AlloysᎭ Miniature cast part. Core slides, also called moving die components Al 380 Mg AZ91D Zn No. 3 Zn 2, 3, 5, 7, ZA-8 or moving die parts, are similar to collet or cam movements and can be activated by various Part Size Range .75” x .75” .75” x .75” .75” x .75” Minuscule to 18” x 18” to 18” x 18” to 18” x 18” to 4” x 4” x 1” sources of motion. Two of the most common are angle pins and hydraulic cylinders. Part Weight Range .5 oz. .25 oz. .5 oz. 1/14 oz. (2g) The angle pin is a mechanical source of motion to 10 lbs. to 10 lbs. to 8 lbs. to 3/4 lb. (337g) activated by the opening and closing of the die. Machine Tonnage Range 200-800 tons 80-650 tons 150-500 tons 4-Slide Miniature Its advantages are that it does not require Vacuum-Assist Availability Yes Yes No No hydraulics or limit switches, and is generally more economical to manufacture. Its limitations are that Expected Die Life 1X 3X to 5X Life of Part Life of Part it can be used only for short slide travel and there Ꭽ Table values are approximations. Part sizes shown, for example, in some cases will is no control over the cycle of the slide pull. require center gating of a part, not always practical with particular part designs. The hydraulic method of slide motion permits a choice of cycles, the placement of slides on any side of the die and avoids interference when removing the casting from the die, as is the case critical that the customer discuss such specifica- with the angle pin. tions in detail in the earliest review meeting. The choice of these and other methods of slide Location of the casting’s parting line, as well as its motion depend on factors such as production vol- gate, overflows and vents, must not interfere with ume, the size of die, the length of travel of the or blemish any of the part’s designated cosmetic slide, the size of area being cored out and the surfaces. specific configuration of the part. Normal, incremental die erosion in production is CWM will always make the most cost-effective inherent in the die casting process. Where there recommendation for the particular core slide are cosmetic requirements, special die mainte- suited to achieve the desired result. nance procedures to extend the ability of the die to continue to produce parts to the required high- Importance of a Casting’s Parting Line quality surface finish must be discussed. Second- The parting line is that perimeter on the casting ary surface finishing, such as polishing or buffing, which is the separation point of the two halves of may be complementary to such needs. (Refer to the die casting die. This line affects which half will As-Cast Finish Guidelines on page 10.) be the “cover” die half and which will be the “ejector” half. Assuring Longer Die Life This line also influences any tolerances that The number of parts which can be die cast from a must be held in this area of the cast part. set of die casting dies, before cavity replacement, Tolerancing standards are specific to part charac- is dependent on factors such as the quality of the teristics at the parting line and are presented in die steel used, the alloy specified, the specific more detail on page 9 and in the Coordinate design of part features, and the cosmetic surface Dimensioning section of the NADCA Standards. requirements for the part. Designation of a parting line on a casting draw- While CWM utilizes the highest quality premium ing is an important decision, and is rarely obvious tool steel in all of its die casting die construction, to a designer not familiar with the die casting pro- as well as a proven die surface treatment to opti- duction process. Placement of the parting line mize die life, awareness of design features that must always be the final decision of the die cast- can drastically shorten die life is important for the ing engineer, since its location is essential for the product engineer. casting to meet desired specifications. Sharp internal or external corners should be If there is no cosmetic surface requirement, the modified to reasonable radii. The smooth, highly casting can be oriented in the two die halves to cosmetic as-cast surfaces, of which the die cast- suit the most favorable overall casting conditions. ing process is uniquely capable, can be expected In the case of a part that must have a cosmetic to result in shorter die life. surface finish, the cover die half will generally be A comparison of CWM die life by alloy category used to produce a specified cosmetic surface. appears in the table above. This permits the ejector die half to contain the required ejector pins—which assist in ejecting the Die Casting Die Specification Checklist part cleanly from the die after each casting shot— CWM makes available a Die Casting Die as well as any engraved lettering or ornamenta- Specification Checklist which should be consulted tion to be cast into the part. when approaching the production of a new With parts requiring a cosmetic surface, it is design as a die casting.

CWM Design and Specification Guide 7 3 Minimizing Part Porosity ciently in their housing designs. Heat sinks pro- The high metal velocities and pressures used to duced as either die castings or extrusions have achieve the fine product detail, cosmetic surfaces proven most effective in these applications. and high cycle rates unique to the die casting The die casting process offers the product process normally result in some internal porosity, engineer the added advantage of great flexibility in below the “skin” of the die cast part (Fig. 3). housing and heat transfer design. An optimized Porosity levels in a cast part can be defined by heat sink can be incorporated into virtually any die “X-ray” or “sectioning” procedures. CWM utilizes cast housing design. real-time automated X-ray imaging to accurately Unlike a plastic molded housing and extruded document the presence of internal porosity, and heat sink combination, EMI/RFI shielding is a built-in function of a thermally optimized die cast Dense, Chilled Skin Porosity in Center Section housing. All forms of extended surfaces for heat transfer can be die cast: straight fins, “S” shapes and pins. Rectangular fins, easily optimized for width, length and thickness in a die cast design and readily cast in place with the majority of housing designs, are the most commonly used. As with any special part feature, consultation with CWM engineering is urged well before final product designs are agreed upon.

5 Preplanning Post-Cast Machining When machining is to be performed on a die cast- Fig. 3 In a thin-walled die casting, the fine-grained dense “skin” is a large percentage of the section, as in the sec- ing, a minimum amount of material should be tion above, left, which would contain virtually no porosity. removed so as to avoid penetrating the less The dense “skin” in a thick section (right) represents a dense portion below the “skin” (see Fig. 3). small percentage of the wall. To assure clean-up, an allowance must be provided for both the machining variables and the can provide a recording of all radiographic images casting variables. These allowances are a function for customer review. of specified linear dimension tolerances and part- Minimizing porosity begins with early planning ing line tolerances (refer to tolerancing guidelines in the design of the die cast part and communica- on next section). tion with CWM engineering. If porosity in specific The best post-casting (secondary) machining areas will be detrimental to product function, this results are attained if the die casting is located should be clearly outlined before die design and from datum points that are in the same die half as construction begins, since zero porosity is virtually the feature to be machined. impossible to achieve in a die casting. It is important to discuss any and all secondary Acceptable modifications in part designs can machining requirements with CWM prior to die often be suggested that will greatly reduce poten- design. If consultation occurs early in the design tial porosity problems. Once this important step of the part itself, CWM engineers can often mini- has been taken, CWM can utilize moldflow simu- mize the effect of tolerance accumulation and lation, optimized gating and overflow design, die unnecessary machining. Most important, with a design, special management of the heating and combination of minor part design revisions and cooling lines in the die, and sophisticated process special considerations in the design of the die, control and monitoring to limit porosity to non- higher-density areas can be assured in regions of critical areas of the part. critical secondary machining. When 100% pressure tightness is essential in a If CWM will be contracted to perform sec- die cast part, early CWM consultation becomes ondary machining after die casting, and deliver even more important. the part to size, lesser dimensional tolerances If the specific configuration of a component dic- may be possible. tates that it cannot be cast pressure tight, impreg- A complete presentation of machining stock nation of all castings may be required. (Refer to allowances is given in the NADCA Standards, Pressure Tightness, Sec. 6, NADCA Standards). Sec. 4, Coordinate Dimensioning. Included are examples for stock allowances, machining allowances, linear casting allowances, across 4 Optimizing Part Heat Transfer parting line allowances, maximum stock, and Designers of electronic and related devices must casting dimensions—based on datum points in allow for thermal energy to be dissipated effi- either the same die half or the opposite die half.

8 CWM Design and Specification Guide 6 Tolerancing Guidelines Table 3b Precision Dimensional TolerancesᎭ The extent to which the coordinate dimensioning QUICKGUIDETOCOORDINATEDIMENSIONING guidelines shown here for precision die casting tolerances can be achieved in production for a Die Casting Alloy: Aluminum Magnesium Zinc/ZA-8 given die cast part design is highly dependent on WALL THICKNESSES part size and configuration, shrink factors, and the precise feature in which the dimension is planned. Nominal wall thicknesses that can be die cast are heavily dependent on part geometry. With small castings, wall thicknesses of 0.030 in. (.762 mm) may be Caution: The design engineer should understand that precision dimensions in every feature of a part are not possible in production. Precision LINEAR DIMENSION TOLERANCES tolerances should only be specified in agreed Length of Dimension in same die half upon critical areas, since assuring these toler- Basic Tolerance ±0.002 ±0.002 ±0.002Ꭿ ances nearly always involves extra precision in up to 1" (25.4 mm) (±0.05 mm) (±0.05 mm) (±0.05 mm) die construction and/or special controls in pro- Additional Tolerance for each ±0.001 ±0.001 ±0.001Ꭿ cessing, with additional costs often involved. additional inch over 1" (25.4 mm) (±0.025 mm) (±0.025 mm) (±0.025 mm) Consultation with CWM engineering in the final part design stage is important to cost-effective PARTING LINE TOLERANCES—added to Linear Tolerances 2 2 production and part quality assurance. Projected Area of Die Casting: inches (cm )—Tolerances are “plus” values only Note, in some cases and on specific features, up to 10 in2 +0.0035 +0.0035 +0.003 even closer dimensions than those shown can be (64.5 cm2) (+0.089 mm) (+0.089 mm) (+0.076 mm) held by repeated sampling and recutting of the 11 in2 to 20 in2 +0.004 +0.004 +0.0035 die casting die cavity, in combination with the use (71.0 cm2 to 129.0 cm2) (+0.102 mm) (+0.102 mm) (+0.089 mm) of machine capability studies. Such procedures 2 2 +0.005 +0.005 +0.004 will incur added sampling and other costs. 21 in to 50 in (135.5 cm2 to 322.6 cm2) (+0.153 mm) (+0.153 mm) (+0.102 mm)

Precision Tolerance Qualifications 51 in2 to 100 in2 +0.008 +0.008 +0.006 In the case of Linear Dimension, Parting Line, (329.0 cm2 to 645.2 cm2) (+0.203 mm) (+0.203 mm) (+0.153 mm) Moving Die Component, and Flatness Tolerances, 101 in2 to 200 in2 +0.012 +0.012 +0.008 the complete individual standards for each in the (651.6 cm2 to 1290.3 cm2) (+0.305 mm) (+0.305 mm) (+0.203 mm) NADCA Product Specification Standards for Die Castings manual should be consulted for proper 201 in2 to 300 in2 +0016 +0016 +0.012 (1296.8 cm2 to 1935.5 cm2) (+0.406 mm) (+0.406 mm) (+0.305 mm) interpretation and qualifications. For example, Section 5 of the NADCA manual For projected area of die casting over 300 in2 (1935.5 cm2), consult CWM. provides guidelines on “parting line die shift,” which can result in dimensional variations based MOVING DIE COMPONENT TOLERANCES—added to Linear Tolerances Projected Area of Die Casting: inches2 (cm2)—Tolerances are “plus” values only on a mismatch between two die halves. In the case of Flatness Tolerances, the NADCA manual up to 10 in2 +0.006 +0.005 +0.005 provides design guidelines to aid in specifying part (64.5 cm2) (+.152 mm) (+.127 mm) (+0.127 mm) flatness requirements. 11 in2 to 20 in2 +0.010 +0.007 +0.007 (71.0 cm2 to 129.0 cm2) (+0.254 mm) (+.178 mm) (+0.178 mm) Draft and Cored Holes Precision Tolerances for Draft call for a draft on 21 in2 to 50 in2 +0.014 +0.010 +0.010 2 2 (+0.356 mm) (+0.254 mm) inside walls at 3/4 degrees per side, with outside (135.5 cm to 322.6 cm ) (+0.254 mm) walls requiring half this amount of draft. See 51 in2 to 100 in2 +0.018 +0.014 +0.014 NADCA Standards for draft equations and details. (329.0 cm2 to 645.2 cm2) (+0.457 mm) (+0.356 mm) (+0.356 mm) Precision tolerances for Cored Holes, i.e., die 101 in2 to 200 in2 +0.024 +0.019 +0.019 cast holes planned for tapping, are provided in (651.6 cm2 to 1290.3 cm2) (+0.61 mm) (+0.483 mm) (+0.483 mm) NADCA Standards, in terms of diameter, thread 2 2 +0.024 depth, and hole depth requirements. 201 in to 300 in +0.030 +0.024 (1296.8 cm2 to 1935.5 cm2) (+0.762 mm) (+0.61 mm) (+0.61 mm) Geometric Dimensioning & Tolerancing For projected area of a die casting over 300 in2 (1935.5 cm2), consult CWM. A growing number of design engineers are utilizing GD&T markup on their part engineering draw- FLATNESS TOLERANCES: inches (mm) ings. When used properly, geometric Maximum Dimension of Die Cast Surface dimensioning can help reduce the cost of a die Up to 3.00 in. 0.005 0.005 0.005 cast part by facilitating functional gaging. Product (76.20 mm) (0.13 mm) (0.13 mm) (0.13 mm) engineers not already familiar with GD&T proce- 0.002 0.002 0.002 dures are urged to become so. An introductory Additional tolerance, in.(mm) for each additional in.(mm) (0.05 mm) (0.05 mm) (0.05 mm) discussion, as applied to die cast part drawings, Ꭽ Values shown represent greater casting accuracy involving extra precision in die construction and/ appears in NADCA Standards, together with more or special control in production. (2006 NADCA Standards, Sec. 4A) Ꭾ Based on CWM recommenda- detailed GD&T references. tions. Ꭿ For some zinc designs, tighter tolerances can sometimes be held, with use of artificial aging.

CWM Design and Specification Guide 9 Table 4 Guide to Nominal Metal Remaining by Type of Extension (Flash)

Type of Extension & Nominal Amount Remaining After Degating & Trimming

Operation Thick Gates Thin Gates Parting Line & Metal Sharp Description & Overflows & Overflows Seam Line Extension in Corners ≥ 0.12 (3 mm) ≤ 0.12 (3 mm) Metal Extension Cored Holes

After Degating only Rough within Rough within Excess Only Not Not Extension Remaining 0.12" (3.0 mm) 0.12" (3.0 mm) Broken Off Removed Removed

After Commercial Within 0.06" Within 0.03" Within .015" Removed Not Trimming* (1.59 mm) (0.8 mm) (0.38 mm) within .010" Removed Extension Remaining

* “Commercially trimmed” does not include washing to remove loose material. For very heavy gates and overflows, consult CWM.

The die cast frame, right, the casting), and (2) commercial trimming of die illustrates the appearance of a center-gated die cast- casting metal extension. These NADCA guidelines ing before trimming, represent normal production practice. Precision showing gate, runners and trimming, closer than standard commercial trim- overflow extension. Photo ming, or complete removal of all extension entails below is the same die cast additional operations and should be specified only frame after receiving its when requirements justify the additional cost. normal die cast trimming Note that in some instances, where special sur- operation. In many cases the trim die will require face finish characteristics are not involved, the multiple “slides” similar most economic methods of degating and metal to the die casting die, with extension removal may include a tumbling or comparable attention to vibratory deburring operation, or hand cleaning. quality materials and die design details. Note: All CWM tooling 8 As-Cast Finish Guidelines orders include a trim die that meets or exceeds The die casting process is uniquely qualified to NADCA “Commercial provide metal parts with a superior as-cast exter- Trimming” standards. nal surface, important to many component applications—and essential for consumer product housings and other decorative parts. The NADCA surface finishing guidelines presented in Table 5 classify as-cast surface finishes for die castings into a series of five grades so that the type of cast finish required may be defined early in the product planning stage, and well in 7 Metal Extension (Flash) Guidelines advance of die casting die design. An extension of metal (or flash) is normally formed These guidelines should be used for general on a die casting at the parting line of the two die type classification purposes only, not to take the halves and where moving die components oper- place of specific discussion with CWM regarding ate. A seam of extended metal may also occur the steps necessary to assure satisfying as-cast where separate die parts cast a part feature. product finishing specifications. Such specifica- The cost of required trimming of any cast metal tions should be agreed upon with CWM prior to extension, estimated as part of production costs, die design to assure cost-effective production. can be reduced by preplanning in the part design Note that important steps can be taken in the stages and consideration of the amount of metal planning of part design features enabling an opti- extension required to be removed and the mum surface to be produced in specified areas. removal method to be employed. For exacting cosmetic finishes, extra steps in die Early consultation with CWM can often result in design, die construction and casting production production economies in this removal step. are required, and additional cost may be involved. Table 4, above, is the NADCA guide to the Selection of the lowest finishing grade, commen- types of die casting metal extension (flash) which surate, of course, with the die cast part applica- occurs in typical die castings and the amount of tion, will yield the lowest die and part costs. metal extension material which remains after (1) A detailed discussion of the factors that relate degating (removal of any gates and runners from to success in designing dies for highly cosmetic,

10 CWM Design and Specification Guide thin wall die cast parts, specifically as they relate Table 5 As-Cast Surface Finish Classifications and Final Finish or End Use to magnesium die castings, appears in an article by Chicago White Metal Casting, titled Designing Class As-Cast Finish Final Finish or End Use Dies for Thin Wall, Highly Cosmetic Mg Die 1 No cosmetic requirements. Used as-cast or with Castings. It is available on request from CWM. Utility Surface imperfections (flow protective coatings: The first four as-cast surface finish classifica- Grade marks, rubs, surface porosity, Anodize (non-decorative) tions listed in Table 5, right, relate to cosmetic lubricant build-up, etc.) are Chromate surfaces. Class five, “Superior Grade,” relates to acceptable. the surface specification required over a very 2 Surface imperfections (flow Decorative Coatings: selective area for special applications. Functional marks, rubs, surface porosity, Lacquers Grade etc.), that can be removed by Enamels 9 Further Design Assistance spot polishing or can be cov- Plating (Al) ered by heavy paint, are Chemical Finish As emphasized throughout this guide, product acceptable. Polished finish design details—based on sound die casting part design principles—can greatly influence the costs of both tooling and production parts. 3 Slight surface imperfections that Structural Parts The Engineering Bulletin, Designing Optimum Commercial can be removed by agreed upon (high stress areas) Part Shapes, contains introductory information on Grade means are acceptable. Plating (Zn) Electrostatic Painting developing the optimum product design configu- Transparent paints ration for cost-effective die casting production. This engineering bulletin can be downloaded (as 4 No objectionable surface Special Decorative Parts Bulletin No. 021) in the Engineering Section Consumer imperfections. Where surface CWM’s Website by (see last page). Grade waviness (flatness), noted by Design considerations are treated in detail light reflection, is a reason for throughout the NADCA Product Design for Die rejection special agreement Casting manual, with a chapter specifically cover- should be reached with the die caster. ing the following: utilizing die cast fillets, corners, and ribs to add strength and aid metal flow; 5 Surface finish, applicable to O-Ring Seats or reducing heavy masses in die cast parts; design- Superior limited areas of the casting Gasket Areas ing features that simplify die construction; and Grade and dependent on alloy redesigning to eliminate undercuts. Guidelines to selected, to have an average the proper design of die cast fillets, ribs and cor- value in micro inches as spec- ners also appear in the NADCA Standards. See ified on print. last page for ordering manuals at CWM discount. (2006 NADCA Standards, Guidelines G-6-6-06) CWM sales-engineers, and the CWM engineering staff, are available to make your early design decisions the correct ones for product success. mal distribution can be quickly explored. There has been more than one example of just such early intervention by a Magmasoft process simula- ® 10 Magmasoft Die Flow Simulation tion analysis that resulted in the avoidance of seri- Advanced metal flow simulation software offers ous die casting production issues. the opportunity to determine the precise manner The initial die casting die cavity design can now in which die casting alloy can be expected to flow be based on the die designer’s experience plus into the die cavity for a proposed die cast compo- the results of this invaluable early metal flow data. nent— before tooling design has been completed Another simulation can then and die construction begun. The benefits of be run, based on the proposed revealing specific die flow problems, until recently die cavity design, to validate the very difficult or impossible to predict, are obvious. die design assumptions made. They can now be easily addressed well in Further die design modifica- advance of expensive production steps. tions and simulation iterations The Magmasoft high-pressure die casting may be indicated to optimize the process simulation software system is acknowl- integrity and surface quality of edged as the most advanced current approach to the proposed part, improve die computerized metal flow trouble-shooting at the casting productivity and lower die casting preplanning stage. It is the in-house eventual die casting costs. software being employed by CWM. For more information on the In most cases the software can be effectively Magmasoft system, download applied to a proposed product design using its Tech Brief 23 in the Tech Brief Use of Magmasoft die casting simulation by CWM 3D CAD files even before the die cavity design section of the CWM website has resulted in reduced production lead times, im- has been developed. The design’s expected ther- OEM DC2 Design Center. proved part quality & lower manufacturing costs.

CWM Design and Specification Guide 11 11 Prototyping for Die Casting Machined Prototypes Because high-quality die casting dies represent Product designers have long specified accurately an important production investment, prototyping machined prototypes as test models for eventual of a part prior to tooling design and volume die die casting. Developments in 3D-CAD, CAM and cast manufacturing is a prudent course for a new CNC programming have made the machining product design. alternative increasingly desirable. Beyond 3-D modeling on the computer, a vari- Parts can be machined from billet or sheet ety of prototyping alternatives are being used, stock with CNC machining performed by working including machining from stock (hog-outs), invest- directly from customer CAD files, depending on ment casting, plaster mold casting, and a range the type and accuracy of the files. After transfer to of so-called “rapid prototyping” (RP) techniques. a CAM program interfacing with CNC worksta- Many RP processes produce components in tions, machined prototype total lead times can often approximate plastic resins to near-die cast tolerances, but are Prior to die casting die construc- often too fragile to withstand repeated handling RP production tion, CNC machined prototype for form and fit, let alone functional testing. scheduling. can be produced, matched to the Validating both the functional performance of a Machined stock specified die casting alloy, for proposed part as well as form and fit is usually for hog-out proto- any pre-release requirement— important to the design engineer. types is selected to directly from CAD design files. All prototyping strategies for eventual die cast- approximate the ing production are approximations to the final per- material properties formance of a die cast part, and the strengths of the eventual die and limitations of each must be weighed against casting alloy. CNC the designer’s most important prototyping criteria. machining can produce parts to near identical part Fused Deposition Modeling (FDM) weights and to the FDM rapid prototyping technology enables the specified die cast- production of far stronger RP prototypes in ing tolerances with durable ABS plastic, directly from STL design precise details as files. FDM parts are built and bonded, extruded specified. layer by layer, from 3-D computer data. Validation of form An FDM prototype (shown, left, & with final die and fit under any casting, below) can be geometrically complex and handling condition produced to tolerances of ±0.005 in. (±.127mm). is assured, and Because of the strength of the ABS plas- many functional tic part, it can be evaluated rigorously for tests can be perform and fit and used in many functional formed. Multiple tests. prototypes can be Most RP methods often have difficulty produced for pre- reproducing very tight toleranced sec- production market tions, such as in sections containing ribs, research in the bosses and holes; in these cases preci- same time frame at sion CNC machining can be performed on reasonable addi- the strong FDM ABS part to the required tional cost. critical specifications. For Al 380 die FDM prototypes can be generated on castings, A1 6061- RP prototypes generated for each de- every new die casting project to expedite T6 aluminum plate partment can expedite lead times for production and shorten total lead times by is generally used each casting & post-casting operation. providing advance models to all depart- for CNC proto- ments involved: These multiple FDM mod- types. For Mg els help assure that die designs result in AZ91D die cast- first-piece success and aid in the simulta- ings, AZ31 Mg neous construction of die cast tooling, plate is recom- trim dies, machining fixtures, finishing mended. Zamak 3 stock is available to prototype masks, and any required subassembly Zamak No. 3 zinc die castings. gauges or fixtures. See Collaborative Secondary coatings and finishes can be Engineering discussion in Section 13. applied to machined hog-outs to closely approxi- FDM prototypes in strong ABS can be CWM’s in-house FDM prototyping mate the appearance of the proposed die casting. precision machined to precise specs. capability can work quickly with customer CWM is one of the few North American custom Final casting shown at right. CAD files to expedite die casting projects. die casters with in-house hog-out capabilities.

12 CWM Design and Specification Guide 12 Post-Casting Operations CNC Precision Machining When net-shape die casting is not feasible for a given part design, post-casting precision machining will be used to achieve final dimensional specifications. CNC machining may also be employed when the unit machining trade-off is less costly compared to the investment in particularly complex automated die casting die slide components to achieve net-shape components. At the same time, post-casting machining of die castings is a more complex production process than machining directly from billet stock. This is especially the case with high-tech die castings in general & high-tech Mg die castings in particular. A higher-level of experience in CNC preplanning and machining center fixture design are critical to cost-effective CNC machining of die cast parts. While state-of-the-art machining centers and equipment can usually provide the greatest cost With a depth of experience in machining Al, Mg and Zn alloys, CWM’s in-house precision advantages on high-volume post-casting projects, CNC machining facility, using advanced high-speed centers, assures highest quality results. more conventional machining units and cells may prove more cost-effective on lower-volume work. As outlined in section 5 of this guide, die caster engineer consultation and careful preplanning in the product design stage is critical to quality post- casting machining results. It is essential that all of the specific machining requirements to be exe- cuted after the part has been die cast must be made clear before a design goes forward: prior to any CAD metal flow simulations, prototyping, or the development of die design drawings.

Surface Treatments and Finishing A wide range of proven surface treatment and final finishing systems are available for die cast- Hydraulically interactive fixturing in state-of- When a programmable dedicated CNC the art machining centers makes possible work cell can reduce your costs, it will be ings in all alloys, although many die cast parts are the highest speeds and cutting accuracy. quickly designed and assembled in house. put to use with no surface finishing operations performed after casting and trimming. These surface treatment systems can be used to (1) solely provide a decorative finish, (2) form a protective barrier against environmental or gal- vanic corrosion, (3) achieve pressure tightness if interconnected subsurface porosity cannot be eliminated, or (4) improve a product’s resistance to wear. Non-toxic coatings are available to meet U.S. & European Union environmental mandates. Even when a die casting requires no further surface treatment for decoration, protection or improved performance, a deburring operation is usually recommended.This step removes the metal flash and any burrs, sharp or ragged edges that might remain after trimming, to facilitate handling and any further finishing treatment. The CWM Quick Guide to Surface Finishing for Die Castings, with a comprehensive ratings chart design guidelines to optimize final finishing results, is available by PDF download at the CWM web- CWM offers sample die cast plates In addition to a free Guide, CWM maintains a site’s OEM DC2 Design Center (see last page). for surface finishing comparisons. comprehensive surface finishing data bank.

CWM Design and Specification Guide 13 13 CWM Collaborative Engineering quality planning which can be expected to influ- A well organized custom production resource ence the final engineered die cast product. must work closely with its customers and their Magmasoft® Software Simulation & Die Design end product requirements to develop the precise Working from clean customer computer files, manufacturing protocols and specifications to which can be transmitted by email or Internet meet OEM product engineering’s design intent. FTP, CWM can proceed with initial 3D CAD evalu- CWM has put procedures in place to assure ation of the component design for die casting fol- meeting objectives beyond these basic expecta- lowed by Magmasoft process simulation. tions—to assure more rapid time to market. By CWM’s use of advanced Magmasoft metal-flow structuring adherence to the collaborative engi- simulations and thermal analysis, prior to die neering model described here with every new die design, can flag possible casting problems and casting production project, CWM maximizes the call for minor product feature modifications which customer’s opportunity to reduce unit costs, no amount of later casting process adjustments improve part quality, and accelerate delivery per- would be able to overcome. These simulations will formance. aid in optimizing die gating, runner and venting configurations in the final die design to assure Customer-CWM Interaction proper metal flow and die fill. For more on this Successful collaborative engineering hinges on simulation software in use, see section 10. the timely and accurate exchange of information on the part of all persons responsible for the con- Prototyping for Concurrent Processing ception, design, development, evaluation, produc- Product design prototypes, produced by Fused tion, quality, sales, delivery, servicing, and Deposition Modeling, are generated by CWM in- eventual disposal of the final product. house for every new die casting project. This requires close coordination of functions Advanced FDM output enables quick modeling within the originating company, and both within of accurate parts directly from STL design files, in the external supplier-producer organization and strong ABS plastic, prior to tool building (for between key representatives of the originating details on FDM prototyping, see section 11). company and the supplier. All key elements in the With individual prototypes simultaneously avail- development process should be running in paral- able to each team member, they can be used to lel, rather than sequentially, and product require- validate the die tooling design and provide final ments and concerns considered and die casting die build instructions, aid in accurately communicated concurrently by all parties. drawing up all QA plans, provide trim die construction details required for the part, as well as information for any gauges, machining fixtures, The Collaborative Engineering Model and secondary finishing masks that are indi- To successfully impact on product unit costs, cated—all in advance of production of the first die quality and time to market, Chicago White Metal cast part samples. If CWM is to perform sub- has instituted a special structure and specific assembly operations, arrangements for the tools to implement its collaborative engineering required assembly cells, fixtures, and other mate- commitment. This covers every aspect of CWM’s rials or purchased components will have likewise involvement in the design and production been made in advance, based on the prototype. process. CAM Die Construction CWM Design Team Checklists Final approved component and die casting die The CWM Design Team assigned to each new die designs, together with an approved FDM proto- casting production project interacts with their cus- type, proceed through CAM die construction. The tomer team during initial meetings using a detailed FDM prototype, in the hands of the toolmaker, will New Project Questionnaire. significantly speed die making and assure initial Responses during these meetings help assure construction to precise specifications. that CWM will be in a position to raise all critical With completion of die casting die build, a first design-for-manufacturing issues at the earliest article inspection report and sample will be sub- point in the component development cycle, so mitted for customer approval, at the same time that later, costly changes can be avoided and process capability runs from the die will be made. quality and performance improvements can be introduced at little or no cost. Process Capability Analysis Alternative cost analyses can be drawn up and Sample runs on the specified production die cast- presented for early trade-off decisions, with no ing machine will confirm the process parameters delay in project progress. to be used in full production and the layout for any These focused customer responses should SPC charting that might be designated. cover all aspects of component requirements and When customer approval of the “first piece

14 CWM Design and Specification Guide inspection” report is received, all succeeding pro- non-die cast components from qualified third- duction elements will be established and uninter- party sources and final packaging of assemblies rupted, continuous piece-part production— to your exact specifications. through any required CNC machining, finishing CWM subassembly projects make use of cus- and assembly—can begin. tomized manufacturing cells, specially designed CWM fixtures and experienced materials manage- ISO 9001 On-line Data ment. Well-supervised personnel operate in a As part of the implementation of CWM’s ISO clean, 16,000 sq. ft. air conditioned space. 9001:2000 registered quality system, every department has on-line access to the company’s own ISO manual and updated references. This interactive and searchable electronic data- base facilitates document control and provides instant availability of updated information. Customer Responsibilities A tightened production timeline places additional responsibility on the customer to confirm that all product and design requirements have been signed off on by all relevant company departments before die design begins, and that a timely communications channel is in place between CWM and the key company team leaders.

14 Design File Transfer Options The Engineering Dept. works with a range of media, software and hardware for convenient, rapid OEM design file transfer. CWM can accept customer digital design files for die casting production evaluation and for die design development in virtually every popular format. For complete CAD file transfer information regarding CWM, including preferred 3D and 2D and other file formats, and details on CWM hardware, software & CAD/CAM procedures, visit the CWM Website’s CAD File Transfer page in the Quotation section of CWM’s website: Complete product subassembly operations can be performed by CWM’s Contract (www.cwmdiecast.com). Manufacturing unit, with full responsibility for purchased non-die cast components. Design files can be transferred by email attach- ment ([email protected]) or CWM can access the Customer’s Internet server for secure FTP retrieval or arrange a download via a web link. Contact Sales at 630-595-4424 or email [email protected] for the latest information.

15 Contract Manufacturing With most end products, a die cast part is a component of a larger assembly, precision-mated to other custom and stock manufactured parts. Based on a depth of experience in subassembly production, CWM can offer special efficiencies and complete flexibility in performing this manufacturing role through its CWM Contract Manufac- turing unit. This work can range from limited assembly steps to comprehensive single-source turnkey production of a complex product subassembly, with appropriate testing equipment on- Specialized equipment will be employed, as required, to accelerate cost efficiencies. Here line. Contracts can include the procurement of all an eight-station assembly cell performs two-sided gasketing in volume production.

CWM Design and Specification Guide 15 CWM Design & Specification Resources at Your Disposal Browse CWM’s DC2 To aid OEM product design engineers and specifiers in making the right design- Die Cast Design Center for-die casting decisions early in the product concept stage, Chicago White Metal Over 70 die casting Casting offers a variety of resources for ready access. We counsel and work with design guides and bulletins some of the world’s leading companies on their high-precision components. are available to OEM Design Information from the CWM Website by Instant Download product designers and engineers for download Design Guides, Application/Tech Briefs and Engineering Bulletins mentioned in this 24/7 at our website: guide, are available by instant download from the CWM Website’s DC2 (Die Cast http://dc2.cwmdiecast.com Design Center), which includes Reference manuals & Design CDs available at special CWM discounts. You can also download a copy of CWM’s capabilities brochure. (Browse the DC2— See link at right). CWM Sales-Engineers As an arm of our engineering and sales departments, CWM sales-engineer representatives are located in major design and production centers in the U.S., and in Canada & Mexico. They can answer your initial questions, provide copies of CWM printed literature, arrange for a “Design-for-Die Casting” Seminar at your company or your visit to CWM’s 136,000 sq. ft. facility. They can be located in the Sales Engineers section of CWM’s Website, or by calling Chicago White Metal. Visit the CWM CNC Machining and CWM Contract Manufacturing Websites For a detailed look at CWM’s CNC Machining and CWM Contract Manufacturing capabilities, visit the CNC Machining Technologies and CWM-CM Websites listed below. To discuss a current or future die casting project, call or e-mail CWM.

Chicago White Metal ® Casting, Inc.

Certified Aluminum, Magnesium, Zinc and ZA-8 Die Casting

EXCELLENCEISEXPECTEDCWMISAGREENBIZLEADERCOMPANY

469 N. Route 83, Bensenville, IL 60106-1382 U.S.A. Phone: 1 (630) 595-4424 Fax: 1 (630) 595-9160 Chicago White Metal Casting Email: Website: [email protected] www.cwmdiecast.com CWM CNC Machining Technologies Email: Website: [email protected] www.cnc-technology.com CWM Contract Manufacturing Email: Website: sales.cwm-contractmfrg.com www.cwm-contractmfrg.com

MANAGEMENT SYSTEMS ISO 9001 AND ISO 14001 CERTIFIED

Engineering Representation throughout the U.S. and in Canada & Mexico

MEMBER: North American Die Casting Association

International Magnesium Association