Economical die-cast housings in application-specific geometries

31st May 2023
Sheryl Miles

Die-casting enables the production of electronics housings in application-specific sizes and shapes and offers an economical manufacturing solution even for small-batch production, despite the tooling costs involved.

Since even very complex geometries are possible, CNC reworking is only necessary in areas with especially high requirements for surface quality.

Typical materials for die casting are aluminium, magnesium, and zinc. Based on the required heat dissipation, the desired geometry and application-specific housing characteristics, CTX Thermal Solutions manufactures all housings and, if necessary, takes care of machining and surface finishing, as well as colour-related design aspects. With the aid of the die-casting tool required for the production of the housings, any application-specific housing geometry can be easily reproduced, combining a high-quality design with low costs per piece. It is also possible to provide samples and to modify the design on short notice.

Die-cast housings: advantages due to low costs per piece

Like all metal enclosures, die-cast aluminium enclosures are particularly suitable for high-end applications in mechanical and plant engineering, as well as applications with stringent requirements for heat dissipation or electromagnetic shielding (EMC). However, the main advantage of die casting is the low cost per piece in large-batch production of electronic housings. In the case of large annual production quantities of 500 to 1,000, it is recommended to product a tool with multiple cavities, for a more efficient die-casting process. This substantially reduces the costs per piece.

Aluminium die-cast housings are reliable even in extreme conditions: they are resistant to temperatures and chemicals, feature high impact strength and stability, and also achieve a high IP rating. In many cases, CTX die-cast housings are an excellent alternative to electronics housings from CNC production. CTX provides customer support starting with the project planning stage, including creation of all CAD data, 3D models, and provision of design recommendations for optimisation of the production process.

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