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We’re thrilled by the high level of interest and the questions that enriched the discussion, allowing for a direct exchange on real cases and daily challenges in the industry. A special thanks to our internal experts: Matteo Margiri, Andrea Panvini, Ermo Fusè, Matteo Colombo, and Marco Scaramuccia, for offering concrete insights drawn from their experience at Bruschi foundries, making the webinar even more relevant and practical.

Stay tuned for future in-depth events and updates on industry developments.

Thank you once again for your participation and interest!

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The component in question is linked to the safety of the vehicle’s driver and passengers. Due to its very nature, it requires a maximum tolerance of a few thousandths compared to the required weight of 6 grams. Such a tight tolerance level is challenging to be respected 100% in producing die-cast parts.

Bruschi’s R&D team and technical office took the lead in developing a pioneering project in the sector. Leveraging software development and cutting-edge technologies, they overcame the common limitations of die-casting production and met the customer’s demand.

Therefore, the mass production of zinc pieces smaller than a €1 coin was guaranteed, respecting the tolerance specifications provided by the customer.

Bruschi designed and implemented a fully automated production process to ensure precision and quality. This process involves the use of robots equipped with precision grippers capable of extracting the die-cast components from the molds. A camera placed on the machine allows the robot to independently verify the presence of all the pieces inside the mold, dismantle them, and place them on a precision scale for quality assurance.

Any pieces that do not meet weight standards activate a reject system.

This is an example of how technological progress and engineering skills make it possible to satisfy the market’s needs, overcoming production limits that only a constantly evolving company can overcome.

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Zinc alloys are renowned for their remarkable properties such as their robustness, resistance to corrosion and ease of casting. Over time, the evolution of manufacturing techniques has propelled zinc alloys to the forefront of a wide range of industries, including the automotive and electronics sectors. In this post, we will provide insights into the latest advancements unfolding within the realm of zinc alloys and their development, shifting from cutting-edge innovations to manufacturing breakthroughs. 

Furthermore, we will delve into how these materials will unlock new opportunities and enhance performance standards by revolutionising product development across various sectors.

Lately, slight fluctuations in zinc alloy demand have arisen due to economic slowdowns and changes in global industrial demand trends. Despite these challenges, the ever-expanding automotive industry has remained a constant driver of demand for zinc alloys. Utilization of zinc alloys in critical processes such as die-casting has been instrumental in meeting industry performance and durability standards. As the automotive industry continues to evolve and adapt to changing market dynamics, the role of zinc alloys remains important, providing manufacturers with a versatile and reliable solution to meet evolving industry demands while fostering innovation and sustainability in the manufacturing sectors.

Alongside their mechanical properties, zinc alloys are also valued for their environmental sustainability. Zinc is highly recyclable: recycling rates of zinc alloys have soared to nearly 80% globally. The metal’s recyclability ensures conservation of natural resources and the reduction of energy consumption (and subsequent greenhouse gases emissions) associated with primary metal production, classifying it as an eco-friendly choice for manufacturers aiming to minimize their environmental footprint.
A brief rundown of zinc’s most advantageous properties has been given below.

Qualities of zinc alloys

• Strength and durability

Over time, significant progress has been made in enhancing the strength and durability of zinc alloys. Through precise alloying and innovative processing techniques, researchers have been able to achieve remarkable progress in crafting alloys with higher resistance and improved robustness, which represent significant breakthroughs in the industry. This has expanded the utility of zinc alloys across a spectrum of growing sectors all over the world, immensely benefitting manufacturers. Production of components is now able to more effectively meet the stringent demands of buyers by ensuring greater degrees of performance and longevity.

Among the distinguished zinc alloys (like zamak 2, zamak 3, zamak 5 and zamak 8), zamak, composed by a mix of zinc, aluminium, magnesium and copper, emerges as a prominent contender. Zamak alloys are known for their exceptional strength and dimensional stability, making them perfectly suited for the fabrication of components requiring intricate shapes or stringent tolerances. The versatility inherent in zinc alloys empowers designers and engineers with a variety of options in material selection. Zinc alloys can be specifically tailored to meet specific performance needs, offering a customizable solution that seamlessly aligns with all the needs of its diverse applications. This flexibility not only enhances the efficiency of manufacturing processes, but also underlines the pivotal role played by zinc alloys in driving innovation and unlocking new opportunities in engineering and design. 

• Corrosion resistance

In a wide variety of industries, especially the automotive and construction sectors, corrosion resistance stands as one of the key factors influencing buyers’ choice of material. Historically, zinc alloys have been recognised for their ability to withstand corrosion, owing to the formation of protective oxide layers on their surfaces. However, recent research and development practices have increased their corrosion resistance capacity to new heights, positioning zinc alloys as a leading material, capable of enduring the harshest of environments. These advancements have not only helped in the corrosion resistance property of zinc alloys, but have also significantly extended their service life, ensuring optimal performance in both favourable and challenging conditions.

Across the spectrum of zinc-based alloys, exceptional resistance to corrosion is a hallmark feature. This resilience makes zinc alloys indispensable in applications where exposure to corrosive elements is inevitable. Notably, the presence of aluminium in these alloys adds to their already robust corrosion resistance, further fortifying their suitability for a diverse array of environments. Whether exposed to road salts and harsh weather conditions when employed in automotive components, or atmospheric pollutants when utilized in structural elements of buildings, zinc alloys demonstrate unparalleled resilience, ensuring longevity and reliability. As industries continue to prioritize and value the durability of their products, the corrosion resistance of zinc alloys makes it one of its greatest assets, further helping it shape the landscape of modern engineering and construction practices.

• Customization

One of the most exciting advancements in zinc alloy technology is the capability to customize alloys according to specific application requirements. Through precise adjustments in composition and microstructure, engineers can tailor zinc alloys to yield desired properties like conductivity, thermal stability and resistance. This level of customization not only enhances the versatility of zinc alloys but also sparks innovation in product design. Manufacturers now have the freedom to create components that perfectly align with the demands of their respective industries, pushing the pre-existing boundaries present in the fields of engineering and design.

• Sustainable manufacturing

In the current climate of heightened environmental awareness, sustainability has become a primary consideration in the development of materials. Zinc alloys present numerous advantages in this context, which include their widespread availability, optimal recyclability and minimal energy consumption during processing. Recent initiatives have concentrated on enhancing the sustainability of zinc alloy production through the implementation of efficient recycling methods and the adoption of eco-friendly manufacturing processes. These efforts signify a commitment to reducing the environmental impact of zinc alloy manufacturing, further aligning with broader sustainability goals through responsible resource management.

Innovations in zinc alloy development

Advancements in zinc alloy development have paved the way for innovative applications across various industries. In the automotive sector, zinc alloys improve the safety mechanisms of vehicles and enhance crash performance. Zinc alloys are also finding their applications in the electronics industry and this is possible because of their excellent thermal and physical properties, such as conductivity and EMI (electro-magnetic interference) shielding. Additionally, zinc alloys are increasingly being adopted in the medical sector for surgical instruments and implants, benefiting from their biocompatibility and corrosion resistance.

The market for zinc alloys has been witnessing significant technological advancements such as additive manufacturing, which, paired with the advent of new material compositions, have helped expand the reach of zinc alloy applications. Companies in the sector are increasing research and development to create new alloys offering superior performance, energy efficiency and environmental benefits, all of which will come to the aid of manufacturers and customers alike.

Future outlook

Looking ahead, the future of zinc alloy development appears promising, with ongoing research focused on enhancing performance, expanding metal applications and boosting sustainability. With the help of advanced computational modelling techniques and additive manufacturing technologies, we can expect to see even greater innovation and diversification in the design and application of zinc alloys.
One of the key trends likely to shape the zinc alloy market is the increasing demand for sustainable and environmentally friendly materials. The alloys are anticipated to evolve in response to stricter environmental regulations and the push for greener materials in the manufacturing value chain.

Market forecasting is a critical component for businesses and investors looking to make informed decisions in this sector. Trends suggest a moderate growth trajectory for the zinc alloy market, with regional hotspots potentially altering market dynamics through accelerated demand and innovation.

Conclusion

In conclusion, the advancements in zinc alloy development marks a significant milestone in the realm of materials science and engineering. Extraordinary features of zinc alloys encompass strength, durability, remarkable customizability and sustainability, and enable zinc alloys to continually push the limits within modern manufacturing. As research and innovation continue to evolve, these materials are positioned to assume an increasingly important role in shaping the technologies of tomorrow.

The zinc alloy market stands as both essential and dynamic, thus exposing companies within the sector to a wide range of challenges, but most importantly opportunities. Through strategic decision making and the use of comprehensive data and analysis, players in the market can look to anticipate and capitalize on emerging trends, driving sustainability and profitability over the long term. With a proactive approach and an eye towards innovation, companies can ensure a prosperous and successful future for the zinc alloys market, as it promises to be one of the most resilient.

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This important victory was achieved thanks to the creation of an aesthetic component for the steering wheel of a car of a well-known car manufacturer made by Bruschi on behalf of an important Tier 1 in the automotive sector.

The competition, organized by the North American Die Casting Association (NADCA), was created to promote the growing use of die casting in the various market sectors and rewards projects that have distinguished themselves over the last year in three categories of materials such as aluminum, zinc, and magnesium, then declined into weight classes.

The aesthetic component made by Bruschi won first prize during the Die Casting Congress and Exposition 2021 in Indianapolis on October 5, 2021 thanks to the motivation of being the first zinc alloy component ever assembled on a car steering wheel. Bruschi’s skills and the use of zinc alloy have made it possible to obtain advantages such as rigidity, stability, and robustness, as well as the possibility of a high-quality finishing, which other materials could never have obtained.

This success is the fourth NADCA prize awarded by Bruschi in the course of its history and projects the company towards new ambitious objectives to be achieved, always intending to be at the forefront of the die casting market and continuously receptive to new techniques and methodologies to apply to everyday operations to contribute to the improvement of the sector. Click here to discover all the awards won by the Bruschi.

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The conference will present a statistical process analysis project, developed with Minitab software, formed from the collaboration between Bruschi and HH & Partners with the patronage of the University of Bologna and the University of Naples Federico II.

A project born following the attendance by Roberto Rodolfo Gaggianesi, Senior Process Engineer of Bruschi, of a Six Sigma Black Belt master and which consists of a statistical process analysis elaborated on an automotive component of an important Tier 1 customer of Bruschi performed through the Minitab statistical software.

Roberto, in his advanced training, was able to develop the project thanks to a consultant of the master, university professor of Bologna and leading expert in statistics, as well as a partner of the company HH & Partners managed together with an expert in fluid dynamics of superalloys, formerly researcher at Rolls Royce, now Big Data Scientist at a US multinational.

The project is focused on finding a correlation between a set of input parameters, such as speed, pressures, and characteristics of the injection profile, with a set of output parameters, such as weight, burrs, and surface quality.

In detail, the development of the project made it possible to:

• Optimize input parameters according to customer requests, moving from a ‘try and learn’ approach to a more structured approach;
• Lay the foundations for the transition from a feedback logic to a real-time feed-forward logic.

This research has therefore allowed Bruschi to increase its performance in terms of operations and forge an important collaborative relationship with two of the most prestigious Italian universities that will lead to further future developments in terms of innovation.

The whole Bruschi team is looking forward to April 4, 2022, to understand how the project will be judged by the expert audience of the Minitab Insights 2022 Global Conference.

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AESI is the new Bruschi department that deals with automation and its integration into complex systems. AESI creates, in partnership with the customer, new machines for specific functions related to mass production processes. In fact, it is not a question of simple integrations between systems, but it is a careful analysis of each component that makes up the project.

The method is to define the project through a research process carried out together with Bruschi customers, perform simulations, select the potential suppliers by purchasing the necessary components, design the management software and directly produce the key elements of the machine.

From the logic of the process to the design, up to the implementation of the machine working with technologies and skills in the fields of Robotics, Artificial Vision Systems, Pneumatics, Dosing Systems, Coding and Induction Heating Systems.

The development of this department will allow Bruschi to expand the range of solutions to better support customer needs.

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The old web domain has been abandoned to improve company webpages’ indexing outside of Italy: considering that over 80% of Bruschi production is delivered to international customers it is important for the company to be easy to find from every country. This choice will help the company with starting its American subsidiary, Bruschi USA, by giving potential customers a portal to learn about Bruschi values and production system.

However, Bruschi is mainly an Italian company and this is why Bruschitech.com has been entirely translated: the Italian version of the website is available at Bruschitech.it. On the website are published both translated versions of latest blog posts and some main Company News, to keep up to date with the company development and events.

Why Bruschitech?

When it comes to choosing a new web domain, independently from its topic, it is very likely to slip into a common problem: the name may be already taken, especially in case of simple and short ones.

To overcome this issue, an internal survey was organized to choose a new domain’s name: every employee should suggest up to 3 domain’s names, knowing ahead the unavailable options. Among the received proposals, Bruschitech.com obtained the most votes.

Employees’ participation in choosing new domain’s name made the change of domain a shared decision, increasing involvement and affiliation between the employees, in addition to offering a break from everyday work and a chance for a good laugh thanks to some witty and bizarre suggestions.

Moreover, it felt fair that employees could express their preference on the topic, since Bruschi mail format will change with the web domain.

From now on, company email addresses new format will be: @bruschitech.com.

Every new mail will be sent from these addresses, but all the mails sent to @bruschispa.it are still going to be correctly delivered, in order to make the transition easier for customers. This means that Bruschi clients and suppliers should not experience any interruption in communication with Bruschi.

Bruschi CEO, Paolo Rastelli, declared: “Our new web domain merges the know-how of our Marketing team with Bruschi drive towards new technologies in a concise and effective manner, without over-shading the industrial nature of our company. The fact that it was chosen by the majority of our employees adds an even greater identity value to the name, allowing us to improve our international indexing without diminishing our company identity.”

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This is the reason why every year the company organizes many update and formation courses:  not only they allow us to grant that the most recent safety standards are respected, but they also contribute to the professional growth of our employees, by giving them a chance to specialize, adding an extra value to their working time: a value marked by their newly obtained skills.

In 2017 all kinds of courses were held, involving our whole working force: classes on new simulation tools, training courses for foundry workers and forklift drivers, skill strengthening courses for management and safety courses.

Metallurgy course

At the end of 2016 began a course on metallurgic techniques and production processes, held by Eng. Andrea Panvini. In each module some of the fundamental steps of die casting where discussed and explained, from the design of the channels to complex calculation of parameters and injection sections, up to recognition of defects in the quality of die casted products.

One of the main topics was how to identify the causes behind the defects, to strategically intervene and prevent porosity and other defects.  The majority of the common defects in casting can actually be solved either in the design phase, or by adjusting the mold or the injection system. During the course the focus was on how to evaluate the efficiency of the injection system, depending on the pressure of the stroke, the duration of the filling process and the surface quality required.

It was an advanced level course, oriented at improving the knowledge and skills of our technicians and our Engineering department.

Simulation course

During the autumn some of our engineers, experts in the use of simulation software, attended an update course aimed at comparing different programs available on the market. The newly acquired knowledge of these programs will make it possible to better exploit their functionalities, by integrating and comparing the data obtained, securing more precise results.

Lean manufacturing course – 5S

In order to improve the organization and ease units management, from the beginning of June 2017 a cycle of lectures were held by Eng. Bruno Vicaretti, aimed at applying the 5S methodology in the whole plant. The 5S methodology was born in Japan with the goal of speeding up processes of integrated logistic by improving the workspace, reducing the operational time. The system is named after the 5 steps that compose it:

1. Seiri, sort
2. Seiton, set in order
3. Seiso, shine/sweeping
4. Seiketsu, standardize
5. Shitsuke, sustain

 This course involved the warehouse, the tool shop and the foundry. The results achieved are already visible:

Toolshop
Before                                                                                           After

Foundry
Before                                                                             After

Warehouse
Before                                                                              After

Management skills strengthening course

In the autumn another course took place: it was dedicated to the analysis and strengthening of management skills of Bruschi’s team. It was a series of meetings with workshops and tests, with the goal of defining and developing a cross-field skill set, spacing from intellectual/cognitive skills to achievement/management and relational proficiency.

Foundry workers course

In parallel to the previous metallurgy course, formative lessons for foundry workers were held. The goal was to cover theoretical and practical basic notions of die casting, in order to support and simplify everyday activities related to the functionality of the plant and machineries. The topics discussed ranged from maintenance to safety, from the correct use of tools to quality control.

At various times of the year health-and-safety courses were organized, aimed at avoiding workplace injuries and reducing fire hazard, in addition to specialization courses for forklift drivers and technicians.

All these investments in employees training take us further in our path of constant improvement, both in productivity and working environment, and allow us to meet our clients demands with innovative and original solutions. These moments are not just necessary to learn new notions, but are also fundamental shared moments of reasoning and confrontation on future plans with a new, shared vision.

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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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