Real project stories behind tooling, quality, and delivery decisions
These case studies show how KastMfg supports OEM programs where leak rate, machining stability, thermal performance, and launch timing matter as much as piece price.
Case Study
Case Study: Zinc Padlock Body -1.2M Shots, Zero Zinc...
How KastMfg eliminated 3.2% plating rejection on Zamak 5 padlock bodies by switching to SHG zinc ingot with spectrometer-verified purity and...
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Case Study: Tool Transfer and Quality Recovery
How KastMfg onboarded transferred die casting tooling, corrected process instability, restored first article approval...
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Case Study: Magnesium Laptop Chassis -40% Weight Red...
How KastMfg produced AZ91D magnesium die cast laptop chassis achieving 40% weight reduction versus A380 aluminum, with Grade A cosmetic surface...
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Case Study: Supplier Switch Reduced Finished Part Cost
How KastMfg helped an industrial equipment buyer switch die casting suppliers, stabilize quality, and reduce finished component cost through tooling...
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Case Study: LED Streetlight Housing -Thermal & Coast...
How KastMfg solved a 150W LED streetlight housing failing 800-hour salt spray -switching to A360 alloy, e-coat primer...
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Case Study: Hydraulic Manifold -A413 Pressure-Tight...
How KastMfg produced A413 hydraulic manifold blocks passing 350 bar burst and helium leak tests -using VADC, mold flow simulation...
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Case Study: EV Motor Housing -Vacuum HPDC + T6 Struc...
How KastMfg solved a BEV motor housing requiring T6 heat treatment, IP67 cooling jacket, and H6 bearing bores -using vacuum-assisted HPDC to achieve...