Facility spotlight: Dynacast Elgin

Multi-award-winning die casting facility

Dynacast Elgin produces over a million precision zinc and aluminium die cast components each day from its 112,000 square foot facility. While that number alone is impressive, the real story lies in its people and the number of award-winning components this facility has produced. We believe that the foundation of any successful project lies in component design. For Dynacast Elgin, that starts with its engineering team, winners of two International Die Casting Design Awards this past year.

While the award-winning components were created for automotive applications, each had very different functions and was previously produced using a different manufacturing process. The over 6oz category winner was previously a machined aluminium extrusion assembly. The Dynacast engineering team redesigned the part as a single component, using Zamak 3 and incorporating the necessary mounting features. The under 6oz category winner was previously a stamped component. Using the facility's state-of-the-art software, the Elgin engineering team modified this part and designed it for the die casting process, resulting in a higher-strength component than the previously stamped version. Both redesigns reduced the overall part cost for the customer.

The team takes pride in helping customers determine the best materials and processes to deliver the best results for their business. They are driven to produce any component that customers bring to them. With over 12 NADCA die casting awards, the Elgin engineering team has successfully demonstrated that its design for manufacturability techniques can create components that other die casters simply cannot.

Dynacast in-house capabilities

Using design, prototyping and modelling services, Dynacast Elgin provides manufacturing solutions to customers throughout North America. Not only does Elgin build its tools in-house, it also operates 9 aluminium die casting machines and 76 Multi-Slide zinc die casting machines—ranging from 4-600 ton clamping force and part sizes varying from 1g to 7lbs. In addition to its wide range of die casting machines, Elgin has over 25 CNC machines—plus dedicated tapping, reaming and drilling machines—far exceeding the capabilities of other die casters.

Additionally, Elgin's specialist secondary manufacturing department and robust network of certified suppliers support many best-in-class manufacturers across a variety of industries, including medical equipment & devices, telecommunications, consumer electronics and automotive, including both electronic and safety-critical components.

Operational excellence

Elgin was one of the first Dynacast facilities to implement FOS (Form Technologies Operating System.) The FOS platform incorporates a coordinated set of procedures for identifying problems, implementing changes and developing easily repeatable systems that can be adopted into everyday practices. By using 5S and other lean manufacturing techniques, Elgin has drastically improved overall plant performance, resulting in a positive impact on its customers. This new philosophy is not merely a strategy implemented by management, but a culture that has improved the team's way of thinking, enabling it to maximise productivity and reduce waste.

Dynacast Elgin is the recipient of the NADCA safety award for achieving an outstanding record that exceeds national manufacturing averages. 

Midwest NAFTA die casting company

Dynacast Elgin is a NAFTA-certified die casting company that works with organisations around the world, helping bring their ideas to life with high-quality die cast components. Using only certified alloys, Elgin delivers the results its customers need with the cost-effectiveness their business demands. Learn how to simplify your die casting process and reduce costs, contact Dynacast Elgin today to speak with a member of its local team or request a plant tour.