Case Studies
We solve active die casting problems by turning complex design specifications into reality. Here are a few examples of how PHB has helped OEMs reduce cost, improve quality, and accelerate launches.
Automotive
Automotive Lighting Housing
Challenge: A complex, thin-walled lighting housing suffered from porosity and warp at a previous supplier.
Result: MAGMAsoft® simulation and a redesigned gating system reduced scrap by 70% and eliminated warp.
Communications
Multi-Cavity Zinc Connectors
Challenge: An OEM needed higher volume on small zinc connectors without sacrificing tolerance.
Result: A new four-cavity tool doubled throughput while holding critical dimensions within ±0.002 in.
Appliances
Large Appliance Casting
Challenge: A large aluminum transmission housing required casting, machining, and leak testing from one source.
Result: PHB consolidated three suppliers into one, reducing total landed cost and lead time by six weeks.
Military
Legacy Part Reverse Engineering
Challenge: Drawings for a legacy defense component were unavailable.
Result: CMM and 3D scanning produced accurate CAD models and new ITAR-compliant production tooling.
Choose PHB for your die casting & machining needs
Take advantage of PHB's 100+ years of die casting experience. Call us today at 814.474.5511 or request a quote online.