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<p>Dynacast Elgin, the 112,000 square foot facility,&nbsp;is located to the northwest of Chicago on 4.3 acres of land. Just 45 minutes from the Chicago O’Hare International Airport, Elgin supports Illinois, Michigan, Wisconsin and as well as other areas throughout North America. &nbsp;The secondary manufacturing department specializes in high-volume and high-speed tapping. Below are additional details about what is offered at the Elgin location:</p><ul><li>76 multi-slide zinc die casting machines ranging from 4 to 65 tons</li><li>9 aluminum machines up to 500 tons</li><li>24 CNC machining centers</li><li>Precision tool building with in-house capabilities</li><li>Design, prototyping, and modeling services</li><li>Wide range of finishing surfaces available including tumbling, polishing and shot blasting</li><li>Wide range of secondary operations including CNC machining, tapping, reaming, drilling, thermal deburring, x-ray, in-line vibratory feeder, and spectrometer</li><li>Network of certified suppliers that can offer any cosmetic or protective coating you may need to finish your product</li></ul><p></p><p></p><p></p><p></p><table><colgroup data-width='920'><col style="width:31.30434782608696%"/><col style="width:33.91304347826087%"/><col style="width:34.78260869565217%"/></colgroup><tbody><tr><td><p></p><figure style="text-align: center"><div data-img-caption-container="true" style="display: inline-block; text-align: center;"><a href="https://formtechnologies.my.salesforce.com/sfc/p/60000000KJ3S/a/UV000004RqjN/bmeQ6c.YhR.0_ocznd44ILLT9vDBJy8a9WkNUugZEqM" target="_blank"><img width="51" alt="6.png" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt2b9da23d1638440c/67b49e964a18e33d8cd111ad/6.png" height="51" target="_blank" style="text-align: center;"/></a><figcaption  style="text-align: center;" >IATF 16949:2016</figcaption></div></figure></td><td><figure style="text-align: center"><div data-img-caption-container="true" style="display: inline-block; text-align: center;"><a href="https://formtechnologies.my.salesforce.com/sfc/p/60000000KJ3S/a/UV000004Rquf/Zy9ZcozDYRqJDLIpwhGflQcsBjOxPS973TpSnZ6sTi0" target="_blank"><img asset_uid="blt2b9da23d1638440c" width="51" alt="6.png" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt2b9da23d1638440c/67b49e964a18e33d8cd111ad/6.png" height="51" target="_blank" style="text-align: center;"/></a><figcaption  style="text-align: center;" >ISO 14001:2015</figcaption></div></figure></td><td><figure style="text-align: center"><div data-img-caption-container="true" style="display: inline-block; text-align: center;"><a href="https://formtechnologies.my.salesforce.com/sfc/p/60000000KJ3S/a/UV000004Rr7Z/DxnDuIag1B1Mbe9C69MkdGewv3txB4o3kzmV3lSrQZE" target="_blank"><img asset_uid="blt2b9da23d1638440c" width="51" alt="6.png" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt2b9da23d1638440c/67b49e964a18e33d8cd111ad/6.png" height="51" target="_blank" style="text-align: center;"/></a><figcaption  style="text-align: center;" >ISO 9001:2015</figcaption></div></figure></td></tr><tr><td></td><td></td><td></td></tr></tbody></table><p></p>

Elgin

Dynacast - Elgin - L3

Elgin, IL

<p>Dynacast Lake Forest is located in Southern California’s Orange County. They are dedicated to die casting zinc alloys with both conventional and multi-slide machines, as well as die casting aluminum alloys. With a dynamic and highly skilled workforce in Southern California, Dynacast Lake Forest is able to provide better service and state-of-the-art technology to new and existing customers.&nbsp;Below are additional details about what is offered at the Lake Forest location:</p><ul><li>34 multi-slide zinc die casting machines ranging from 4 to 28 tons</li><li>9 conventional zinc die casting machines ranging from 80 to 200 tons</li><li>20 aluminum die casting machines ranging from 135 to 580 tons</li><li>Precision tool building with in-house capabilities</li><li>Tooling design, Design for Manufacturing (DFM), prototyping, and modeling services</li><li>Wide range of finishing surfaces available including tumbling, polishing, shot blasting and thermal de-burring</li><li>Network of certified suppliers that can offer any cosmetic or protective coating you may need to finish your product</li><li>Wide range of secondary operations including CNC machining, tapping, reaming, and drilling</li><li>Conventional, CMM and &nbsp;x-Ray inspection, advanced ultra-sonic cleaning, installation, assembly and test operations including electrical, air and water leak testing</li></ul><p></p><p></p><table><tbody><tr><td><figure style="text-align: center"><div data-img-caption-container="true" style="display: inline-block; text-align: center;"><a href="https://formtechnologies.my.salesforce.com/sfc/p/60000000KJ3S/a/UV000004RrM5/r0cIc.FyYew1Ci_J4mmFWbfbTgWWjxIn0_X_y8YCxOU" target="_blank"><img asset_uid="blt2b9da23d1638440c" width="51" alt="6.png" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt2b9da23d1638440c/67b49e964a18e33d8cd111ad/6.png" height="51" target="_blank" style="text-align: center;"/></a><figcaption  style="text-align: center;" >IATF 16949:2016</figcaption></div></figure></td><td><figure style="text-align: center"><div data-img-caption-container="true" style="display: inline-block; text-align: center;"><a href="https://formtechnologies.my.salesforce.com/sfc/p/60000000KJ3S/a/UV000004RrVl/1CRv65Gbhppk1SJh0.SXE1G00ggadxyggY207hihxfQ" target="_blank"><img asset_uid="blt2b9da23d1638440c" width="51" alt="6.png" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt2b9da23d1638440c/67b49e964a18e33d8cd111ad/6.png" height="51" target="_blank" style="text-align: center;"/></a><figcaption  style="text-align: center;" >ISO 14001:2015</figcaption></div></figure></td><td><p></p></td></tr><tr><td></td><td></td><td></td></tr></tbody></table><p></p>

Lake Forest

Dynacast - Lake Forest - L3

Lake Forest, CA

<p>Dynacast Mexico is located to the north of Mexico City. As a die cast supplier in Mexico, this plant is dedicated to die casting zinc and aluminum alloys using both conventional and multi-slide die cast machines. Our Mexico die casting facility has also been a front-runner in increased process automation. Below are additional details about what we offer at the Mexico City location:</p><ul><li>28 multi-slide proprietary zinc die casting machines ranging from 4 to 65 tons</li><li>12 standard zinc machines ranging from 80 to 200 tons</li><li>15 aluminum machines ranging from 350 to 580 tons</li><li>22 CNC machining centers</li><li>5 shot blasting machines</li><li>4 tumbling machines</li><li>1 thermal de-burring machine</li><li>1 High pressure cleaning machine</li><li>Precision tool building with in-house capabilities</li><li>Design, prototyping, and modeling services</li><li>Wide range of finishing surfaces available including tumbling, polishing, shot blasting and thermal de-burring</li><li>Network of certified suppliers that can offer any cosmetic or protective coating you may need to finish your product</li><li>Wide range of secondary operations including CNC machining, tapping, reaming, and drilling</li><li>AIAG compliant delivery system for automation management at customer warehouses&nbsp;</li></ul><p></p><table><tbody><tr><td><figure style="text-align: center"><div data-img-caption-container="true" style="display: inline-block; text-align: center;"><a href="https://formtechnologies.my.salesforce.com/sfc/p/60000000KJ3S/a/UV000004RrYz/474ksmd4tMdEc3XcL2vUg0kIMvYx98v_e4mEBV.DZK4" target="_blank"><img asset_uid="blt2b9da23d1638440c" width="51" alt="6.png" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt2b9da23d1638440c/67b49e964a18e33d8cd111ad/6.png" height="51" target="_blank" style="text-align: center;"/></a><figcaption  style="text-align: center;" >IATF 16949:2016</figcaption></div></figure></td><td><figure style="text-align: center"><div data-img-caption-container="true" style="display: inline-block; text-align: center;"><a href="https://formtechnologies.my.salesforce.com/sfc/p/60000000KJ3S/a/UV000004RrcD/ecFRLNqDPz8XZHNJY15BL.4bC9DGtHehcgS7BGugQ1k" target="_blank"><img asset_uid="blt2b9da23d1638440c" width="51" alt="6.png" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt2b9da23d1638440c/67b49e964a18e33d8cd111ad/6.png" height="51" target="_blank" style="text-align: center;"/></a><figcaption  style="text-align: center;" >ISO 14001:2015</figcaption></div></figure></td></tr><tr><td></td><td></td></tr></tbody></table><p></p>

Mexico City

Dynacast - Mexico City - L3

Mexico City, MX

<p>Dynacast Peterborough is known for its multi-slide technology, standard die casting with integrated automation, and IMA (Injected Metal Assembly) precision zinc manufacturing. IMA, a type of insert molding, offers a unique process where precision tooling is combined with metal alloys and is used to join multiple components into a ready-to-use assembly with a single operation. The facility also features advanced aluminum hot chamber multi-slide capabilities, which include fast cycle times (up to 10 cycles per minute), a very low runner-to-casting ratio, and fully-automated in-line processing that produces flash-free components. Dynacast Peterborough is dedicated to designing, building, manufacturing, and delivering quality die cast components. Below are additional details about what is offered at the Peterborough location:</p><ul><li>36 standard zinc die casting machines ranging from 12 to 21 tons</li><li>12 standard zinc die casting machines ranging from 70 to 200 tons</li><li>2 hot chamber multi-slide aluminum machines operating at 20 tons</li><li>5 Injected Metal Assembly (IMA)/Insert Molding machines up to 1 ton</li><li>Precision tool building with in-house capabilities</li><li>Design, prototyping, and modeling services</li><li>Wide range of finishing surfaces available including tumbling, polishing, shot blasting and thermal de-burring</li><li>Offers cosmetic or protective coating equipment either through certified suppliers or in-house</li><li>Wide range of secondary operations including CNC machining, tapping, reaming, and drilling</li></ul>

Peterborough

Dynacast - Peterborough - L3

Peterborough, ON

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<p>New to the die casting process? Learn how to effectively implement design tactics for optimal manufacturability here.</p><h2>Design for manufacturability</h2><p>Optimizing your component design to take advantage of the die casting process is the key to seeing a return on your investment. Whether your project is best suited for conventional die casting, multi-slide die casting, or injected metal assembly, it’s best to design your component with the production process in mind. In other words, engineers should approach each project with the intent of designing for optimal manufacturability.</p><p>Design for manufacturing (DFM) is a core methodology that ensures that die cast parts perform to specification and reduce the need for secondary operations. Considering that these operations can often represent as much as 80% of the component cost, it’s important to minimize them during the design stage.</p><p>DFM is more than just a concept—it’s a way to remove cost and eliminate inefficiencies before your project moves towards production. <strong>In this blog, we’ll walk you through three ways to design your die cast component to get the most ROI.</strong></p><h2>Reduce weight and wall thickness</h2><p>In die casting, two of your highest cost drivers are the material and the machine time. You can reduce the need for both by adding weight-saving pockets and thinning your walls.</p><p>Reducing weight and wall thickness in cross sections may seem like an obvious answer. Less weight means less material, and less material means lower material cost. It also means decreased solidification time, which means that you get more shots per minute. However, some companies find themselves sacrificing performance for cost.</p><p>With part performance in mind, it’s important to be deliberate about reducing weight and wall thickness while maintaining part strength. When designing your component, you’ll need to use the mechanical and physical requirements of your project to choose the most appropriate alloy that will perform effectively with thin walls.</p><p>For instance, if your part needs to be corrosion-resistant and stable, thin wall aluminum is a good fit. Aluminum is corrosion resistant and retains a high dimensional stability and hardness.</p><p>Would you like to learn which alloy is the best fit for your project? Use our <em>dynamic metal selector tool</em>  to filter for your required mechanical and physical properties!</p><h2>Maintain consistent wall thickness</h2><p>While striving for a reduced wall thickness, it’s perhaps even more important to maintain uniformity. This will go a long way to ensure a consistently stable, repeatable casting that is optimized for manufacturing.</p><p>Varying wall thickness can lead to porosity from both varying flow pressures and non-uniform solidification. At Dynacast, our engineers have many tricks to achieve a net-shape component with die casting while maintaining consistent wall thickness.</p><p>In Figure 2, you can see that the component on the left has several walls that are much thicker than the thinnest part of the component. If casted this way, it would yield a weaker, porous part. Instead, our engineers will core the thicker walls to achieve more uniformity and incorporate ribs in the cores to guarantee part strength.</p><h2>Consider draft angle and tolerance zones</h2><p>When designing your component, it’s important to keep in mind the achievable draft angles and tolerances for your project’s materials to avoid delays in redesigns. For draft angles, in general, 0.5º is achievable for zinc 1º-2º is achievable for aluminum. For exact tolerances, generally between ±0.001” and ±0.002” is possible for zinc, whereas aluminum can hold between ±0.002” and ±0.004”.</p><p>With achievable draft angles and tolerances in mind, you’re better equipped to avoid engineering unnecessary cost into the design. Too often, companies will request exacting tolerances and minimal draft angles when such features are not needed to maximize part performance. As a result, their castings fail.</p><p>Instead, take a more holistic approach to your design. Determine the non-critical dimensions of your component to allow for more lenient tolerance zones. In addition to extending the life of your tool since there are fewer exact geometries that wear down, allowing for tolerance zones also makes it easier to plan the tolerance stack-up of your entire component. This will help you to avoid machining and secondary operations wherever possible, making your design work for you to get the most out of the die casting process.</p><h2>Work smarter, not harder</h2><p>Modifying your part design to take advantage of the die casting process not only enables you to fully leverage the efficiencies of die casting, but can also better suit your business needs.</p><p>Are you interested in learning more about how to efficiently design your die cast component for optimal manufacturability? Sign up for our webinar, Work Smarter Not Harder: Removing Cost in the Design Stage.</p>

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Understand the basics of die cast design and how to improve part function, durability, and manufacturability with Dynacast.

Beginner's Guide to Die Cast Design | Dynacast

See strategies for optimizing die cast design, including weight reduction, maintaining uniform wall thickness, and understanding draft angles to maximize manufacturability and ROI in your projects. 

A Beginner's Guide to Die Cast Design

<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>

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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

<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>

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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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