In recent times, automotive manufacturers are more focused on manufacturing lightweight automobiles without affecting durability of the vehicles. Therefore, die casting is one of the most valuable techniques adopted by the manufacturers for creating automotive parts. The number of die cast parts used for automobiles continues to rise daily. Some of the main reasons for the increase in demand of die casting by the manufactures are:

Increased precision, efficiency and cost effectiveness

Die casting is a technology that helps in increasing precision, efficiency and cost effectiveness of the automobiles / vehicles that are getting manufactured by using die casted products or components. Die casting is also one of main reason behind numerous automotive advancements that are witnessed by all of us. With the ability to mold materials such as zinc, aluminum and magnesium alloys, die casting unlocks various other opportunities that helps in elevating vehicle performance boosting in an overall growth of automotive industry.

Helps in fuel efficiency

The inclusion of die cast components in the automobiles, mainly in engines, also helps in fuel efficiency as the overall weight of the vehicle reduces when die casted components are used which also results in lower emissions resulting in reduction of pollution and better vehicle performance that helps in production of more units effectively and efficiently.

Increased automation and flexibility

The popularity of automotive die casting is increasing day by day all over the globe due to the high use of advanced technology in almost every industry. All the process becomes more effective and productive when the production process is automated. Moreover, die casting technique helps to create parts with complex shapes and sizes easily which ultimately makes the installation process smoother.

As discussed above, die casting helps to produce parts with complex shapes with high durability and improved aesthetic appearances. Following are some of the parts / systems from wide variety of applications of die casting for automobiles that includes:

• Engine parts
• Mounting brackets for electric motors and stepper motors
• Electronic covers for gearbox
• Sensor and airbag housings as active safety mechanisms
• Fuel intake parts
• Air conditioning systems
• Mounting brackets for stepper motors
• Retractor spools for seatbelts
• Transmission components
• Sensors
• Chassis components
• Durable power steering and braking systems

Advancements in die casting technology

As automotive manufacturers strive to stay at the top of innovation and adapt to new technologies, die casting technology has evolved to meet the growing demands of the industry which also helps the manufacturers to product the vehicles with the new technology that also helps in customer satisfaction. Some of the main advanced die casting techniques are playing a crucial role in achieving higher levels of precision and efficiency in automotive industry such as:

1. High pressure die casting

High pressure die casting involves injecting molten metal into a steel mold at high pressures that results in faster cycle times and enhanced part integrity of the vehicles. This type of die casting technology helps in the production of complex automotive components with minimal porosity, ensuring the highest quality and durability.

2. Vacuum die casting

In vacuum die casting, the process is carried out in a controlled environment with reduced air pressure. This method minimizes gas porosity in the final product that is being produced, further also improving the structural integrity of the automotive components. In recent times, manufacturers are increasingly adopting to vacuum die casting for manufacturing the critical parts, such as engine components and safety mechanisms.

Innovations in die casting materials

With the aim to create light weight yet robust automotive components, die casting industry has witnessed continuous material innovations. The incorporation of advanced alloys, such as zinc – aluminum alloys, has become prevalent. These alloys not only offer improved strength and durability to the vehicles but also provide a higher degree of corrosion resistance to them. The composition of the materials can also be customised as per the requirements which results in enhancing the overall performance of die – cast automotive parts.

This customization capability not only focuses on specific performance requirements but also opens various opportunities to include die casting materials for diverse applications in manufacturing other different components for automobiles. As a result, the evolution of die casting materials is not just about meeting the current industry needs but also about anticipating and adapting to future technologies and challenges in the automotive manufacturing industry.

Sustainable practices in die casting

In response to growing environmental concerns among the individuals and manufacturers, the automotive industry along with various other industries is also increasingly focusing on sustainable practices for most of the processes. Die casting foundries are also collaborating with many automotive manufacturers to implement eco – friendly measures in their production and all other operations. This includes the use of energy – efficient equipments, recycling of process water and the implementation of green manufacturing practices. This aligns with the automotive industry’s commitment to reducing its carbon footprint.
By aligning the die casting processes with sustainability goals, the automotive industry is moving towards a more environmentally responsible approach that will not only help the environment but will also help the companies in the long run.

Future opportunities

In the ever – evolving industry of die casting, several new and trending opportunities are emerging which is helping to push the industry towards enhanced capabilities and efficiency. Let us have a look at some of the possible future opportunities that lies there for die casting industry with respect to automotive industry.

New materials and alloys

Research into new materials and alloys is opening opportunities for enhanced die casting capabilities. Materials with improved strength and durability are being explored to meet the evolving needs of the automotive industry that will help in the manufacturing of different types of parts and components for automobiles that will be having more stability and resistance to make the final product much better from now.

Smart manufacturing and industry 4.0

The integration of smart technologies and industry 4.0 principles enables real – time monitoring and control of die casting processes. Predictive maintenance, data analytics, estimation of demand – supply and automation contribute to increased efficiency and reduced downtime which helps in the overall growth of the manufacturers as well as of the automotive industry.

3D printing and prototyping

The unification of 3D printing technologies in die casting processes allows for rapid prototyping and the creation of complex geometries that are required in day-to-day basis in automotive industry. This innovation accelerates the product development cycle of the parts and components that are manufactured and supports the customization of automotive components.

Collaborative research and development

Collaboration between die casting manufacturers, automotive companies, and research institutions fosters a scope for continuous improvement. Shared knowledge and expertise can lead to breakthroughs in die casting technology that can also help in analysing the challenges that are faced in the correct manner and take corrective actions and measure to tackle them.

Conclusion

In conclusion, the innovation and efficiency in automotive industry has led to the widespread adoption of die casting techniques, particularly in the manufacturing of light weight and durable components. Die casting not only enhances precision, efficiency, and cost – effectiveness but also contributes to fuel efficiency, automation and flexibility in the production processes that are done for the production of parts and components of automobiles. The diverse applications of die casting in creating complex parts for engines, safety mechanisms and various automotive systems throws light on its pivotal role in shaping the future of the automotive sector with the help of die casting in the process.

The evolution of die casting technology, including high – pressure die casting and vacuum die casting, showcases the industry’s commitment to achieving higher levels of precision during the process of production. Material innovations for die casting are also resulting in contributing to create robust and lightweight automotive components. Moreover, the industry’s increasing focus on sustainable practices focuses on environmental concerns emphasizing a responsible approach towards reducing the carbon footprint.

Looking forward, the automotive industry anticipates exciting opportunities in the near future, including the exploration of new materials and alloys, the integration of smart manufacturing and industry 4.0 principles, the adoption of 3D printing for prototyping and collaborative research and development initiatives. The points mentioned above not only promises improved and enhanced die casting capabilities but also signifies a collective effort towards continuous improvement.

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In 1948 the company was founded by Giuseppe Bruschi with entrepreneurship and a big desire of innovation. Today in 2018, the same mission still guide the company: every day a new beginning, every beginning as a new challenge.

To deal with the new challenges that every day the market puts on the table, Bruschi relies on the core pillars of its business: technology, co-design and mass production. These pillars are the backbones of the everyday actions, the tools within the company differs and creates added value for its customers.

The creation of added value to those who trust in Bruschi is the everyday aim in our company: of engineers, of managers e of all the complete staff.

For this reason Bruschi complement to its productive capacity, in terms of mass production, its forefront technology and its co-design services in order to achieve a perfect collaboration between the customer and the supplier.

These dedicated services and the innovation are part of an integrated vertical approach to die casting, that starts from the idea and finish with the coming into the market. A process, defined by years and years of experiences in the field as different section supplier, brought Bruschi to its first 70 years.

These the word of Paolo Rastelli, Bruschi CEO: “We are young seventy years boys, with a big longing to learn, to innovate and a solid will to undertake new roads, new paths. Our vertical integrated approach to die casting, formed by industries and service themselves, complement to our flexibility and innovation capacity, allows us to deal with new challenges everyday. We are not afraid of complexity, on the opposite we believe that is able to bring new incentives and new energy; that we try to transmit with everyday work. Complexity, competition and challenges that belongs to Bruschi history: to the past, to present an to the future. A future full of challenges, as the new Bruschi plant in the US, that will start its production in October. After 70 years the ability to stay young”.

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As the Journal of Industrial Engineering International reports, customers are more and more calling for environment-friendly products and this demand puts pressure on the whole supply chain, because it involves manufacturers, suppliers, retailers and customers. The latter are asking for a greener supply chain that promotes environmental protection and, at the same time, are also developing a well-defined purchasing behavior, which avoids unsustainable products and services. Businesses are therefore studying new methods in order to reach green supply chain management (GSCM), the integration of environmental issues and supply chain that results in reducing manufacturers’ impact on environment while enhancing an organization’s performance.

White goods recycling system

As far as white goods are concerned, emphasis is placed on their recycling cycle: manufacturers must therefore focus on materials. According to AHAM, the Association of Home Appliance Manufacturers, household appliances are increasingly being recycled: they are overtaken only by automotive industry as a source of recycled materials. The growing interest towards recycling has allowed to achieve significant results in the household appliances industry, also thanks to the United States Environmental Protection Agency, specifically with the Responsible Appliance Disposal (RAD) program, which in 2017 has recycled almost 70 million pounds of ferrous metals, 4 million pounds of nonferrous metals, 17 pounds of plastic and 3 million pounds of glass. As data highlight, consumers are increasingly aware of the importance of recycling and are more and more adopting a responsible and sustainable purchasing behavior: white goods industry is therefore continuously renovating and appliances’ manufacturers must face new challenges that environmental consciousness generates, developing products with recyclable materials through sustainable processes.

Metals recycling

White goods are characterized by a long life cycle, normally 10 to 18 years, and when they are no more usable they provide a consistent amount of recycled materials, specifically metals. As stated by The Global Metal Waste and Recycling Market report, the most recycled metals are iron, steel, aluminum, copper, lead and zinc; in addition to that, the report indicates the leading recycling industries, which are building, automotive, shipbuilding and consumer appliances. Metals are among the main materials that undergo a recycling process: they are perfectly suitable for recycling, indeed metals are valuable, can be easily transported thanks to their density and, furthermore, they present properties that allow them to be recycled repeatedly. In the U.S. metal recyclers manage thereabouts 120 million tons of recycled metal every year, with the metal recycling industry having registered nearly $27 billion in 2018.

Zinc recyclability

White goods are complex machines composed of several elements and different materials, among which zinc represents an intelligent and recyclable choice. As a matter of fact, zinc has exceptional metallurgical and chemical properties that remain unchanged also after recycling process, making zinc a suitable material for a wide range of modern products, such as white goods and small appliances.

To calculate zinc recycling rates experts rely on two main methods: the End of Life (EoL) recycling rate and the Recycled Content. Usually EoL is preferred because it measures the quantity of available zinc recovered at the end of product life and recycled, whereas the Recycled Content approach considers the amount of recycled material in a given product. Recent analyses report that around 45% of zinc at the end of life is estimated to be recovered and recycled; in developed regions, such as Europe and North America, this percentage reaches 50%.

Typical Recycling Rate Indices

What is more, zinc not only is itself recyclable, but also contains numerous substances that are recyclable: this quality certifies zinc as Cradle-to-Cradle (C2C), a concept inspired by nature that promotes circular economy. According to this approach a product is designed already considering future reuse and, at the end of its life, it is seen as a new source instead of waste: materials and elements that compose the product are thus recovered and again inserted into the processing cycle.

Zinc benefits in white goods manufacturing

Taking into consideration customers’ request for quality products manufactured with sustainable practices, zinc constitutes an ideal material for white goods components. Indeed, zinc presents high recycling rates and excellent aesthetical quality, combining two of the most demanded characteristics by end-users. Highlighting zinc properties can therefore be an efficient promoting strategy, thus meeting customers’ expectations, providing environmental-friendly solutions and improving selling rates.

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Starting a new branch is always a venturesome initiative that needs to be planned carefully. The preparations began some months ago and they will culminate in new plant opening next September, in the Great Lakes region, near the Chicago area.

Bruschi USA facility is aimed at providing future customers with the same punctual services and tailored solutions as it was done for so many years in Europe. Every project, developed since Bruschi foundation, has helped to improve its method and enrich its know-how, which will be now transferred and actively applied in the new factory.

Bruschi USA will offer the same services that have characterized Bruschi in Europe: from idea, through mold design and construction to all the mechanical operations and surfaces treatments, necessary to reach clients expectations: finished products ready for the market. A vertical integrated approach: that is the signature of Bruschi work in Europe.

Bruschi President & CEO Paolo Rastelli said: “With our new division Bruschi USA, in September we are going to start the production in North America to bring our vacuum technology in zinc die casting, our co-design service and innovative surface treatment integrated in a vertical approach into the US. It will be the beginning of a new journey for Bruschi, that will open new doors and further enrich our experience.”

For any further information you can check Bruschi USA dedicated page: Bruschi USA

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The event has become a traditional appointment for Bruschi: it is a Career Day reserved for small and medium sized business, reserved for students, graduates and undergraduates of the scientific faculty of the University.

A day in which all the participants can interact with the exhibiting companies, ask questions to stands referents and learn about the possibilities to start a career within the local factories and industrial headquarters.

For Bruschi this is a great opportunity for recruiting and for exchanging information with the next players of the industrial world. An important moment, that makes it possible to describe the worklife and to define in the best possible way the daily flow of a company that interacts everyday with the most important global manufacturers.

For this reason the company deems fundamental to take part in PMI DAY 2017, just like it takes in great consideration all those activities of research and collaboration carried on together with the Politecnico of Milano as a way to be a main player in the markets.

Every year the collaboration between Bruschi and Politecnico of Milan becomes closer: the development of shared projects with an high innovation value and Bruschi’s becoming a hub among the favorite destinations for Mechanical Engineering Graduates are the most evident results of this cooperation.

For further information Bruschi invites you to its stand.

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The Observatory SME, based on the ownership model through which Global Strategy select companies autonomously, analyses financial statements and data of more than 40.000 Italian companies of manufacturing and services. They focus their attention on 7500 businesses which have a production value between 20 and 250 million euros. From this range of reference there is a selection of companies which, in the last five years, have go beyond the sector average of 10 strict economic, financial and patrimonial parameters. In ten years of work, this database has selected more than 2000 excellent companies, it has established more than 250 direct contacts between entrepreneurs and properties on distinctive factors.  On 2016 Global Strategy identified 522 Excellent companies out of 7500 SME total, it means 7% of companies in question.

It is an important success for our company added to technical recognitions awarded the previous years, such as NADCA and IZA.

Mr. Maggiori, Bruschi Vice President & Head of Sales, at the award ceremony in Milan

Paolo Rastelli, Bruschi’s CEO, stated: “ This award is for us the confirmation of our capacity of doing business and the approval that in the last years our company build a system able to lay the foundations for the future. It is a very important award for us as an industrial reality, a further confirmation that Bruschi is an excellence not only regarding technology and innovation but also in its globality as financial statements can show. A great success which reinforce our philosophy of growing and spread our managerial capacity. This award summarize the work of all our collaborators  which, in the last years, helped us to reach these results. A moment of confirmation, as a piece of the mosaic in our strategy of balanced growth, which leads us to look at the future with the awareness of our capacities and values. A new impetus needed to improve and think about next years with further certainties, with the possibility to reach sustainable results”.

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AUTOMOTIVE DIE CASTING Exterior PARTS: ZINC 

Related to automotive die casting exterior parts important to say that zinc die casting has many different benefits such as:

– Cost saving: zinc die casting has a process that offers a wide range of shapes and components if compared to other manufacturing techniques
– Precision: zinc die casting technique allows to produce complex shapes with closer tolerances. Moreover is possible to produce heat and wear resistance part that are dimensionally stable but maintaining close tolerances
– Excellent finish: is possible to manufacture parts with smooth and textured surfaces easily plated with a minimal surface preparation
– Longer tool life: is possible to produce millions of identical parts before a new tooling is required

Now we will deeply analyze why using zinc can be considered a plus in automotive die casting parts. In details zinc alloys can be used for interior parts or exterior parts. A previous post explains how zinc die casting can improve the perception of car interior value (click here for the post) while, in this article, the subject will be more focused on external parts of a car.

Why producing exterior car parts with high pressure zinc die casting

As said is possible to use high pressure zinc die casting both for car exterior parts and for interior: in this article we will analyze car exterior parts. In fact hereunder are listed the most common exterior car parts, or components of that, which can be produced using high pressure zinc die casting.

• Sun roofs
• Door opening system
• Pumps housing
• Symbols+signs
• Tank filling cover
• Rear lamps
• Antenna

The reason to choose zinc alloy is simple because this material has a better combination of toughness, bearing, rigidity, strength, performance and economical castability if compared to other materials.

High pressure zinc die casting is useful to produce components aligned to customers’ requirements.

For these reasons is possible to obtain innovative shapes and unconventional finishing, eliminating extra machining operations and cutting unnecessary costs. In order to produce parts or products aligned to functional or aesthetical aspects, high pressure zinc die casting can be used as an advantage.

To get an overview about zinc benefits in automotive read the following case studies about door opening system and sun roofs.

CASE STUDY n° 1 – The unexpected zinc weight role: door opening system
For a leading player in door handle systems, specialized in automotive, Bruschi produces special counterweight for locking parts. In this case, zinc alloys added value thanks to its specific weight: surprisingly, in terms of automotive, in this case weight is an advantage. Zinc die casting technology allows to strictly control the weight of the product: in this way, weight becomes a functional factor of the systems.

CASE STUDY n° 2 – No secondary operation for the required surface roughness: sun roofs
For an important car manufacturer tier 1 Bruschi produces brackets with guides for car sunroof. These brackets with guides are very precise running guides with complex shapes. Thanks to zinc die casting technology these components do not need secondary operations for the required shapes and even for the grade of surface roughness.

Develop automotive die casting parts in co-design way

To develop products and solutions like that is necessary a strict collaboration between the client and the die casting supplier. This process is fundamental to realize a product that has technical characteristics requested for its functionality and its aim and is at the same time in compliance to the process of die casting, finding the most suitable solution for the car.

This co-design activity is composed of three different phases: Process design, Cost analysis and Product design. In each step the collaboration between die caster and client it should be involved. Following a brief explanation of that.

Process design
In process design phase is important to define the different steps in the production cycle related to the die casting process, taking into consideration multiples variables among different departments.

Cost analysis
The second step about cost analysis is necessary to analyze how much the entire process will cost: a cooperation between parts can be the way to find the economic efficiency of the product, both for the die caster and for the customer.

Product design
The last phase is about product design where the analysis of the shape, geometry and function of the product are related to mechanical characteristics, resistance to static and fatigue stress, aesthetic quality and functional features. Based on the customer’s needs this is the step where an experienced and skilled die caster can make the difference.

To get a complete overview about the importance of product design in die casting engineering: Click here

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Foundry 4.0: digitalizzation and connections

The key point is related to the new value developed in terms of connections, about the ability to build a network system among humans, machines and new tools thanks to digitalizzation. By following this philosophy Foundry 4.0 it is a means to an end, not an end in itself representing a tool that allows to work in different ways. These different ways can help to create connections: the real added values of that process that are fundamental to improve business.

Data are the proof of that.

In fact, according to an Accenture Research called “Innovation-Driven Growth”, market leaders which invest in innovation and integration of digital technologies to offer differentiated customer experience show an increase in annual turnover between the 3% and 7%. Investment in innovation could determine a virtuous circle between companies, from supplier to customer, among common services useful for both sides. Sharing data in real time using the same software, back-end tool for businesses to facilitate the use of services by clients, common dashboard to manage the supply chain network can increase the collaboration: to increase performances and get an important saving in economics and timing terms.

This is the way to use tools and make connections.

Foundry 4.0 is a great opportunity for industry. Digitalization allows quicker decisions given by a deeper analysis of data and a better awareness of every production sector. It’s a new industrial revolution and it’s only the beginning of it.

In Bruschi making connections in all its supply chain and with its clients is one of the most important challenges for the company.

Bruschi CEO Paolo Rastelli said: “Bruschi for 10 years has had a deep digitalization software that handled the production and foundry. Now with our new software we are able to link other sectors of the company, to manage data and analyse production data: casting activities, secondary operations inside the productive plant and organize Bruschi supply chain suppliers. A conjunction of tool, which allows data integration: starting from machine data, secondary operations or integrated communications with suppliers parts. This can be considered a second approach to Industry 4.0, that extends company potential and its results already reached by the company in the past 10 years”.

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The point of view of Paolo Rastelli, Bruschi CEO and president

In digitalization years no company can really say to be competitive if it is not able to be innovating. It is not only being technology advanced but also to anticipate developments to anticipate clients’ requests.

For this reason Bruschi can be defined as ground breaking in Industry 4.0. The company has anticipated many themes, constantly searching for innovation among advance software.

Stain is an important example of all this concept: it’s an important tool that is part of a wide innovation system that is used daily by the company.

A constant evolution that aims to excellence.

1) What is for you Industry 4.0?

It could be a really great opportunity for industry. It is a challenge for every employee that can give advantages in terms of performances and waste. Digitalization allows quicker decisions given by a deeper analysis of data and a better awareness of every production sector. It is a new industrial revolution and it is only the beginning of it.

2) Why did you choose to become an Industry 4.0 company?

In reality the company did not choose to be part of Industry 4.0 but, technology tools already in plant and a constant work on innovation in terms of software, have put Bruschi in Industry 4.0 companies: in fact for 10 years the company has had a deep digitalization software that handled the production and foundry. Now with Stain software we are able to link other sectors of the company: to manage data and analysis of all our plants. This is a second approach to Industry 4.0, that extends company potential and its results already reached by the company in the past 10 years. A natural passage for us.

3) Your company was ready for this passage?

Bruschi path in Industry 4.0 started when there wasn’t a definition for this industrial revolution. For this reason Bruschi can be seen as a ground breaking in Industry 4.0. It’s a continual process, that is strictly related to technology innovation: for this reason in 2017 Stain will be operative.

4) How the idea of bringing Stain in the company was borned?

In the company a system linked to production demands was needed: a software developed for small companies like Bruschi. Our sector is full of variables and chances that a software like Stain allows to manage. The passage between the two systems, the one in use until month ago and the new one Stain, has been completed and since few weeks the company is able to handle better its production.

5) Has been a though experience to take Stain to the company?

In Bruschi an important digitalization was already in act, so it’s not a radical change. The most difficult moment has been handling the change with both systems working, that has been handled at the best by every manager and employee involved.

6) How did employees reacted?

Really good. Every change is appreciated in the company. There had been tough moment but the job was done in the best way possible, reaching the aims. Now the company is linked entirely to the systems and many projects have already started.

7) Do you see other steps in terms of digitalization in the future?

Of course. It is an innovation process that is continue: a constant change of competences with other industrial sectors that is going to continue in our future. There will be innovation trends with systems allowed to increase their performances but it is difficult to bet on which sector will evolve more. There will be digital innovation and Bruschi will try to be ground breaking to give solutions to its customers, in fact there are other projects that are being studied in these days.

8) Which are the keywords to define Bruschi experience?

Innovation, digital and interesting.

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