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: EV Motor Housing -Vacuum HPDC + T6 Structural Casting | KastMfg
How KastMfg solved a BEV motor housing requiring T6 heat treatment, IP67 cooling jacket, and H6 bearing bores -using vacuum-assisted HPDC to achieve Class 1 porosity.
Case Study
Case Study: Hydraulic Manifold -A413 Pressure-Tight at 350 Bar | KastMfg
How KastMfg produced A413 hydraulic manifold blocks passing 350 bar burst and helium leak tests -using VADC, mold flow simulation, and 100% production pressure testing. No impregnation.
Case Study
Case Study: LED Streetlight Housing -Thermal & Coastal Durability | KastMfg
How KastMfg solved a 150W LED streetlight housing failing 800-hour salt spray -switching to A360 alloy, e-coat primer, and fin geometry revision to achieve 1,200+ hour salt spray and 6°C thermal improvement.
Case Study
Case Study: Magnesium Laptop Chassis -40% Weight Reduction | KastMfg
How KastMfg produced AZ91D magnesium die cast laptop chassis achieving 40% weight reduction versus A380 aluminum, with Grade A cosmetic surface, passing drop test and paint adhesion requirements.
Case Study
Case Study: Zinc Padlock Body -1.2M Shots, Zero Zinc Pest | KastMfg
How KastMfg eliminated 3.2% plating rejection on Zamak 5 padlock bodies by switching to SHG zinc ingot with spectrometer-verified purity and redesigning gate velocity -achieving 1.2M shot die life.