Zinc die casting price at the Euroguss

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Euroguss
At the Euroguss the Zinc Die Casting Award of the Initiative Zink was awarded. Among other things, a small case, a shower spray or a housing for X-ray dental technology were awarded.

Criteria for the evaluation were the degree of innovation, construction, design and technical complexity. Applicants could submit components for the categories automotive, sanitary engineering, lifestyle, electrical & mechanical engineering, medical technology, security & locking technology.The jury consisted of zinc producers, zinc alloy producers, die-casting machine manufacturers, as well as representatives of institutes, universities and metal associations. It had evaluated more than 20 submitted parts and had come to this conclusion:

Sanitary engineering:
Cover rosette shower head for Grohe Rainshower Serie, HDO Druckguß und Oberflächentechnik GmbH
Statement of the jury:
The prize-winning component is a large-area application of zinc die-cast as a shower head. The large surface area of the cover rosette of a head shower for the Grohe Rainshower series in combination with a galvanic surface treatment makes special demands on the surface flatness. The galvanisable surface of the zinc die-cast workpiece in a high-quality application, as required in sanitary engineering, has no sink marks and no cold flow (cold flow lines). The production of such large-area zinc die-cast products with a corresponding overall height and a component weight of over 2 kg requires special heat distribution in the casting tool and a powerful die-casting machine. The areas of the casting run and gating system require a special design so that the casting tool, which is characterised by many openings and stabilising webs, can be filled quickly and evenly. This zinc die-cast component replaces a brass component milled from solid diamond material and thus meets the requirements for identical appearance and function. Under these conditions, the component has been redesigned to be suitable for die-casting.The jury honoured the casting from the Rainshower series for its high degree of innovation in casting technology and the implementation of high technological requirements. The jury considers the high surface quality, which in the past could only be achieved by a milled component, and the casting technology requirements for the large-area component to be implemented in an exemplary manner in this casting.

Locking systems:
Cylinder housing shells and head cap for ABUS-ECO locking cylinders
Statement of the jury:
Groß Druckguss GmbH received this award for the implementation of the housing shells and a head cap for ABUS-ECO locking cylinders. Products in the lock sector are characterised by extremely low tolerance ranges, high fitting accuracy and precision. The lock components require high material strength to ensure reliable burglary protection. In addition to the requirement for low manufacturing tolerances on the component, the precision of the mould construction must be emphasised. The result shows the possibilities offered by zinc die casting in mould construction and in the finished product. Zinc die casting delivers quality on the level of conventional mechanical processing. This casting technique offers the advantage of producing large quantities at a high level of quality and under the aspects of low manufacturing costs and resource-saving use of material.The jury honoured the cast parts for ABUS-ECO locking cylinders for the high degree of innovation of this component in the locking technology category. This application of zinc die-casting demonstrates the usability and economic efficiency of zinc even in areas which were previously implemented using mechanically machined workpieces. Due to the precision in mould making as well as in the cast lock components, the award-winning components are an outstanding example of zinc die-casting technology.

Medical technology:
Housing X-ray dental technology, Dipl.-Ing. Siegfried Müller Druckguß GmbH & Co. KG
Statement of the jury:
The award-winning casting is characterized by a completely different zinc die casting property than strength, filigree and thin-walled. Due to its use as a component of an X-ray machine, thick walls, tightness and also precision are required. In addition, the cast part has to meet the highest requirements for shielding against electromagnetic radiation. The cast housing is used in an X-ray unit in dental medicine. It serves as a tank for a low-viscosity transformer oil in which the X-ray tube is located. These requirements make the cast part, which initially appears voluminous and sluggish, a highly complex component. In addition, the entire assembly is fitted with numerous attachments made of zinc die-cast, whose attachment points must be taken into account in the casting process, even on the tank itself. This represents a particular challenge for the design of the runner and gating system as well as the die casting machine. Due to the good properties of zinc for shielding against X-rays, it is possible to largely dispense with additional cladding, e.g. with lead, for the casting.The jury emphasizes the special implementation of the requirements for the component. In addition to the challenge of casting a large-volume and thick-walled component in combination with a great deal of mass, the jury considers the implementation of the requirements for precision, tight shape and position tolerances and the necessary tightness against radiation and highly viscous liquid to be remarkable. The component demonstrates in a special way the wide range of possible solutions that can be implemented with zinc die casting.

Lifestyle:
Case for Wendt & Kühn Engelsfigur, Heiligenstädter Reißverschluß GmbH & Co. KG
Statement of the jury:
The award-winning casting "Suitcase" is based on the original of a suitcase and is a decorative part in the series of collector's pieces made of wood. While many decades ago, suitcases were still made of leather, a separate edge protection with leather corners was applied to the corners. At first sight, the case from the zinc die-cast series looks like a simple cast part. Only at second glance can the attention to detail and precision be seen. The cast case is based exactly on the natural model. The eight corners of the case are minimally small, each projecting 0.2 mm from the actual body of the case. The case lid of the decoration part is also precisely manufactured and is 0.5 mm from the original all the way round. This small component is very big in the implementation of the mould construction and the design of the ejectors in the mould. Thanks to the intelligent solution of ejectors moving at an angle, the mould does not require any mechanical slides at all. The required precision and absence of burrs also places special demands on the production of the mould. With regard to the small parts of the workpiece and the requirements for the material surface, which is electrogilded in the further processing, the mould construction is true watchmaking work. The casting shows impressively that even the smallest quantities are interesting for zinc die casting.The jury awarded the "Suitcase" component with the winner's trophy in the "Lifestyle" category due to the special challenges in toolmaking for the implementation of the small and detailed cast part.

Electrical Engineering:
Busbar for ebm-pabst Fan, Georg Frank GmbH
Statement of the jury:
The award-winning casting is a very filigree, long and sensitive component as a single part. Four individual and very thin conductor strands with dimensions in the tenths of a millimetre range have to be cast in a cross-section of perhaps just one square centimetre. The production of the long flow paths in the casting tool for this conductor rail with plug area and the associated design of the entire tool could only be implemented with a mould-filling simulation. This simulation was used to determine the optimum gate geometry, which made the high casting quality possible. As it is not possible to deburr the component by trimming the filigree overall geometry, this step is carried out by a special tool as well as by plastic granulate blasting. The resulting flake-free workpiece is insulated for use as a current-carrying connection by overmoulding with plastic. In addition, the plastic gives the component the necessary stability, precise cable routing and shields any moisture. These properties represent an improvement over the cabling conventionally used. The casting is used as a connecting component in a fan.The jury honored the zinc die-cast component with the winning placement in the electrical engineering category. The precision and filigree of the component with the associated design of the casting mould and the further sheathing by plastic injection moulding are particularly emphasised, as well as the courage and ability to implement such a component using zinc die casting.

Automotive:
Shift lever Automatic transmission, Druckguss Westfalen Behringer GmbH & Co. KG
Statement of the jury:
The award-winning casting in the automotive category is a basic carrier for the gear knob of an automatic transmission in a passenger car. The gearshift knob is within the constant field of vision of the driver and the vehicle occupants, which places very high demands on the surface quality of the visible surfaces and on a high-quality haptic. The use of zinc die casting achieves a much higher value compared to commonly used plastic parts when used as gearshift lever and also generally in the interior. The zinc die-cast part appears cool, resilient and heavy, although at 150 grams it is rather lightweight. The shift lever as a whole lies well in the hand due to its shape and convinces with its high-quality feel. Recessed LED lights are used to display the gearshift lever and its visible areas in the vehicle, and the jury was particularly impressed by the mould construction solution. Since the gearshift lever is almost exclusively a visible surface, an intelligent solution is required for the position of the gate and the moulding. Due to the geometry of the casting, the further mechanical pretreatment and subsequent galvanic surface treatment pose a challenge that was convincingly solved.
The solution to the geometry-related challenges in the production, further processing and surface treatment of the casting convinced the jury to award the Zinc Die Casting Prize for the Automotive category. The component impressively demonstrates that there are applications in the vehicle whose quality requirements can only be met by zinc die casting.