Aluminum die casting

Aluminum

Why choose aluminum alloys

Die-cast aluminum alloys represent a strategic choice in numerous industrial sectors thanks to their unique combination of lightness, strength and design versatility.

The cold chamber die casting process allows for the production of aluminum components with complex geometries, high dimensional accuracy, and excellent surface finishes, reducing the need for subsequent machining. This translates into significant cost savings, especially in high-volume series production.

From a mechanical standpoint, die-cast aluminum alloys offer a good balance between rigidity, strength, and low weight, making them ideal for applications where lightweight is crucial, such as the automotive, aerospace, electronics, and lighting industries.
Furthermore, these alloys exhibit excellent corrosion resistance and good thermal conductivity, making them suitable for protective casings and heat dissipation systems.
The alloys’ properties can be further optimized by selecting the composition best suited to the specific needs of the component.

Aluminum

Why choose aluminum alloys

Die-cast aluminum alloys represent a strategic choice in numerous industrial sectors thanks to their unique combination of lightness, strength and design versatility.

The cold chamber die casting process allows for the production of aluminum components with complex geometries, high dimensional accuracy, and excellent surface finishes, reducing the need for subsequent machining. This translates into significant cost savings, especially in high-volume series production.

From a mechanical standpoint, die-cast aluminum alloys offer a good balance between rigidity, strength, and low weight, making them ideal for applications where lightweight is crucial, such as the automotive, aerospace, electronics, and lighting industries.
Furthermore, these alloys exhibit excellent corrosion resistance and good thermal conductivity, making them suitable for protective casings and heat dissipation systems.
The alloys’ properties can be further optimized by selecting the composition best suited to the specific needs of the component.

Aluminum’s high recyclability helps make it an environmentally sustainable choice, strengthening its role in modern production processes geared towards efficiency and reducing environmental impact.

Complexity, strength and thermal conductivity: the main advantages of aluminum die casting

Case Study

Frame for the screen of an industrial PLC

Product Description: Frame
Dimensions: 326x237x33.8 mm
Function: Support frame for an industrial PLC screen

Main requirements that led to the choice of aluminum alloys:

General flatness 0.30 mm maximum.

Analyzing the filling simulation results allowed us to correctly design the feed channels and discharge masses, positioning them in the most suitable areas to ensure optimal flow of the liquid metal. This ensures a uniform structure throughout the product, avoiding density differences that could cause excessive deformation during the die casting’s cooling.

Rigidity of the structure to accommodate the glass and absence of hanging burrs in any part of the die-cast.

The properties of the aluminum alloy used not only allow for precise filling of all the product details, but also ensure the necessary rigidity for attaching the touch screen.

Due to the presence of critical weld lines, great precision was required in the mold design and construction to prevent the formation of hanging burrs, which are unacceptable in an electronic product. Furthermore, creating a blanking mold with lateral movements required particular attention and precision.

Surface suitable for receiving powder coating treatment.

The correct filling and meticulous management of the die-casting process parameters allowed us to obtain a surface quality suitable for powder coating, respecting high aesthetic requirements, in particular for the exposed frame of the display.

Lightness of structure but with the necessary mechanical resistance.

The excellent flow properties of the chosen alloy ensured optimal filling of the cavity, achieving a homogeneous structure throughout the die-cast part. This preserved the mechanical properties, which proved to be fully suited to the product’s function.

Rapid production cycle.

The cold chamber die casting process ensures rapid production times. In this case, only subsequent mechanical processing was necessary to secure the PCB and ensure electrical continuity. The aluminum alloy, thanks to its excellent conductive properties, effectively met these requirements.

Services

We offer a vertically integrated approach to zinc and aluminum die casting, starting from the idea, to create the most functional products for our customers.

01. Co-Design

Our co-design service, developed in close collaboration with the customer, improves product design and functionality. By analyzing the entire production process, our team performs simulations that enhance both performance and efficiency—saving time and reducing costs.

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02. Tool design and construction

With extensive experience in zinc and aluminum die casting, advanced simulation software, and close co-design with clients, Bruschi develops high-performance molds. These include innovative solutions like the vacuum valve—a technology first pioneered at Bruschi in 1983.

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03. Die casting

Bruschi processes 6,500 tons of zinc and 2,000 tons of aluminum per year, producing over 110 million components using hot-chamber die-casting machines. Our deep knowledge of this technology enables us to manufacture parts with high detail, thin walls, and excellent surface quality—fully tailored to customer needs.

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04. Mechanical Operations

Mechanical processes are an essential part of zinc and aluminum die-casting production. At Bruschi, custom automation and robotics projects significantly reduce production time, delivering ready-to-use components with no need for additional processing.

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05. Painting & Chroming

Zinc and aluminum components offer great freedom in surface finishing. Their smooth, compact, defect-free surface makes them ideal for a wide range of treatments: liquid and powder coating, enameling, chroming, and more. Bruschi supports each client in selecting the best treatment for their project—whether functional or aesthetic.

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06. AESI

Through our AESI division, Bruschi develops dedicated machines for specific mass production needs. With expertise in robotics, vision systems, pneumatics, dosing systems, coding, and induction heating, AESI meets even the most detailed technical requirements of projects worldwide.

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07. Assembling

Bruschi manages every stage of the production process, from zinc and aluminum ingot to final delivery. Assembly is fully integrated into this process. We design and develop robotic and automated systems to reduce cycle time and provide finished, ready-to-ship products to customers around the globe.

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Bruschi Journal

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