The sustainability analysis conducted together with Siemens AG highlighted the tangible benefits of adopting eco-friendly energy solutions. By purchasing 100% green energy, Bruschi has fully achieved its primary goal of reducing its carbon footprint and improving operational efficiency, while significantly cutting CO2 emissions and reducing long-term operating costs.

In conclusion, the integration of renewable energy in factories represents not only an opportunity to reduce environmental impact but also a strategic investment for the future. With Siemens AG’ guidance, companies can embark on a path of sustainability that not only enhances their image but also contributes to building a greener and more responsible world.

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This article explores the significant role of zinc die casting in the electronics industry also highlighting its advantages and applications.

Zinc die casting is a process where molten zinc alloys are injected into a steel die that has been finished with lubricant. Due to their flexibility, impact strength and low melting point, zinc alloys are used for parts production for various industries including the electronics industry. In addition, the casting process takes place at a lower temperature due to the low melting point of the material. This makes the hot chamber die casting process convenient compared to other technologies. In addition, hot chamber die casting is a process th at promotes longer die life and faster recovery time compared to other die casting compatible materials.

Applications of zinc die casting products in various industries

Zinc die casting parts are used in various industries due to its durability and strength. Below is a list of industries / sectors in which zinc die casting components are being commonly used because of its various advantages and benefits that it provides to the manufacturers as well as to the users of the final product.

• Home appliances

Zinc casting is used to make a variety of household items including belts, furniture inserts, door handles and locks. Its strength and dimensional stability make it ideal for use in home appliances.

• Automotive sector

Zinc castings are used in the production of interior fittings in automobiles. These castings are preferred over aluminum because they are stronger. Examples of automotive zinc alloy castings include bearings and steering.

• Mechanical sector

Zinc die casting parts are used to produce engine parts used in mechanics. The properties of zinc, such as corrosion resistance and hardness make it a more desirable option than aluminum.

• Electronics

Zinc die castings are used in the production of electronic components such as energy regulators, switches, ceramic resistors and wall clocks. The zamak – 3 alloy is best suited for these parts because it offers dimensional stability.

Why is die casting used in electronics industry?

Die casting is used in the electronics industry for its ability to produce complex, highly detailed and accurate metal parts in large quantities. The process creates a uniform and consistent parts with a smooth surface finish which is important for housing delicate components. Additionally, die casting can be used to produce parts with intricate shapes, thin walls and tight tolerances which are often required in electronic applications. The process also offers the option of incorporating internal voids and passages for electrical and mechanical connections.

Zinc die casting and aluminium die casting are used to make electronic products. Zinc die casting is used in applications that require high mechanical strength such as connectors and terminal blocks. Zinc has good castability and can be easily formed into complex shapes making it well – suited for die casting. Additionally, zinc offers good electrical conductivity and good corrosion resistance which are important factors in the electronics industry.

Zinc die casting in electronics parts

In the electronics industry, zinc die casting is used to produce various parts. Some of them are mentioned below:

• Connectors and housings

Zinc die cast connectors and housings are widely used in electronic devices to provide robust and reliable connections. The high precision achievable through die casting ensures that these components meet the demanding specifications of modern electronic devices.

• Enclosures for electronic devices and components

Electronic device enclosures play a crucial role in protecting internal components from external elements such as dust, moisture and physical damage. Zinc die – cast enclosures offer a durable and cost – effective solution ensuring the integrity and longevity of the enclosed electronic systems. Zinc’s excellent electrical conductivity also provides good EMI, RFI and ESD shielding.

• Heat sinks

Zinc has a lower thermal conductivity compared to pure aluminium, however if we compare the thermal conductivity between die-cast zinc alloy and die cast aluminium alloy we can see that the thermal conductivity is very similar. Zinc remains a valuable material in many industries. Zinc’s excellent fluidity permits the production of thinner, finer and closely spaced fins that provide a larger surface area but less volume. Zinc is also stronger, stiffer and tougher than aluminum, die-cast aluminum and magnesium. Zinc also offers strong resistance to impact and great flexibility. Some of these characteristics makes zinc an ideal choice for manufacturing heat sinks.

• Chassis and frames

Chassis and frames provide structural support for various electronic components within a device. Zinc die – casting for chassis and frames offers a lightweight yet sturdy solution contributing to the overall structural integrity and mechanical stability of electronic devices.

• Bases and mounting plates

Bases and mounting plates are essential components for securely positioning electronic devices and ensuring stability. Zinc die – cast bases and mounting plates provide a strong and reliable foundation allowing for secure installation and optimal functionality of electronic equipment.

• Handles and knobs

Handles and knobs are user interface components that enhance the ergonomics and usability of electronic devices. Zinc die – cast handles and knobs provide a combination of durability and design flexibility contributing to a positive user experience in various electronic applications.

• Electromagnetic interference shielding components

Zinc alloys possess electromagnetic interference shielding properties making them suitable for components that require protection from external electromagnetic radiation. This is particularly important in sensitive electronic devices where interference can lead to malfunctions.

• Brackets and supports

Brackets and supports play a vital role in securing and stabilizing internal components within electronic devices. Zinc die cast brackets and supports offer reliable structural support ensuring the proper alignment and functionality of various elements within electronic systems.

• Cable glands

Cable glands are essential for providing secure entry points for cables while maintaining environmental seals. Zinc die – cast cable glands offer robust protection against moisture and other external factors ensuring the integrity of electrical connections in electronic devices.

• Bezels and trim pieces

Bezels and trim pieces contribute to the aesthetic appeal of electronic devices while providing functional features. Zinc die – cast bezels and trim pieces offer a combination of design versatility and durability enhancing the overall appearance and user interface of electronic equipment.

Benefits of Die Casting for Electronics

• High accuracy and dimensional stability

Zinc die casting in electronics industry results in consistent and reliable parts that are produced because of its high accuracy and stability in dimensions.

• Enhanced mechanical properties

Zinc alloys exhibit excellent mechanical properties including high strength, durability and corrosion resistance. Zinc is a versatile material with good strength, corrosion resistance, and stability. These characteristics make zinc die cast components ideal for electronic applications where reliability and longevity are paramount.

• Cost effective production

The efficiency of the die casting process contributes to the cost – effective production. Manufacturers benefit from reduced material wastage, shorter production cycles and lower energy consumption making zinc die casting an economically viable option.

• Design flexibility

Zinc, with its complex and intricate melting point, can be cast into a variety of shapes making it a popular option for many different designs.

• Precision and complexity

Zinc die casting enables the production of highly intricate and complex components with tight tolerances. This is crucial in the electronics industry where small, precisely engineered parts are often required for devices such as smartphones, laptops and other electronic gadgets.

• Surface finish

Zinc die casting is ideal for applications that require a smooth surface finish, which can be easily painted or plated and thus eliminates the need for additional finishing operations.

• Fast production

Zinc casting is an efficient and rapid production method making it well suited for large scale manufacturing.

Conclusion

Zinc die casting has emerged as a key player in the electronics industry offering a winning combination of precision, cost effectiveness and superior mechanical properties. As electronic devices continue to advance in complexity and miniaturization, the role of zinc die casting is likely to expand further that will also contribute to the evolution of the electronics landscape. Manufacturers and engineers are embracing this versatile manufacturing process to meet the growing demands for high quality electronic components in the digital age.

Also, as industries increasingly are prioritizing sustainability and environmental responsibility, zinc die casting also presents itself as an eco – friendly solution. With its recyclability and minimal waste production during manufacturing, zinc die casting itself aligns with the goals of sustainable production practices. Furthermore, the versatility of zinc alloys allows for the creation of different varied designs and shapes which helps in catering to the evolving preferences of consumers in the electronics market. As a result, the future of zinc die casting appears to be promising and it also has a potential to play an integral role in shaping the next generation of electronic devices while meeting the demands of both manufacturers and the consumer.

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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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The customer Schneider Electric has voluntarily adhered to the standard provided by the Responsible Business Alliance (RBA), which aims to promote the improvement of social, environmental, and ethical conditions in global supply chains, consequently also asking Bruschi and all its suppliers to adapt. This audit by Schneider Electric will bring mutual benefits, both for Schneider itself and for Bruschi, such as a better assessment and identification of risks within companies.

The audit process

The audit process began with the first phase of documentation, followed by a plant tour, interviews with staff, and a final analysis of the documentation delivered.

The areas involved during the audit process were mainly occupational/environmental safety and human resources.

The macro topics covered by this certification were the following:

1. Work: the documents concerning rights, contracts, and training processes were analyzed.
2. Health and safety: an examination of the documents on the risk assessment, how personal protective equipment are made available to workers, the training on the subject, and how the entire plant is managed, also including the verification of the presence of fire extinguishers and emergency exits within the company.
3. Environment: the energy diagnosis, how waste is treated externally and stored before being disposed of, and the management of emissions and chemical waste were analyzed.
4. Ethics: Bruschi is currently working on an ethical code faithful to what is established in its sustainability policy.
5. Management system: Bruschi currently has a management system based on the definition of objectives, risk analysis, a training plan, and related communication.

Suggestions for improvement

Thanks to this certification, Bruschi also had ideas for improvement to start working on: an example is creating a Single Point Lesson (SPL) translated into English and French to help and involve workers. Another point to consider with a view to improvement is the installation of a defibrillator. Finally, another theme is Visual Management, for the rapid identification of the first aid team members, the emergency contacts, and the firefighters. Finally, Bruschi is committed to optimizing the 5s method in production, which defines the steps concerning cleaning and order to have continuous improvement and thus eliminate waste.

In short, Bruschi’s goal in the future is further to increase its practices and awareness in terms of sustainability, increasingly integrating the principles of CSR into its business model.

Download the certification!

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Zinc is not only a metal used for die casting: first of all it is a natural occurring element that is essential for life and it is considered a “Life Saving Commodity” by the United Nations. Zinc indeed plays a fundamental role for our planet: it is vital for the natural development of biological processes of every living thing, such as cell division, protein synthesis, immune system and growth. It is therefore an essential element for life.

Furthermore zinc is highly recyclable, when it reaches the end of its life cycle it can indeed be recycled without losing any physical property, thus representing a new source of raw material. Approximatively 45% of available zinc at the end of life cycle is recovered and recycled; in Europe and in the United States this percentage reaches even 50%.

It is exactly this characteristic that is a key element for sustainability and development of a circular economy.

Zinc contributes to circular economy

Circular economy is an economic model based on waste reduction and on the development of a circular life cycle, at the end of which a product is no more considered a waste for disposal but is instead a new source of raw material. Zinc fits perfectly in this model: zinc life cycle indeed starts from mining, goes through refining process in order to be used in the modern society and ends with recycling stage at the end of its useful life. During this cycle zinc contributes in different ways to the well-being of our planet:

• It is highly recyclable, thus reducing need for new raw material and exploitation of natural resources

• It protects steel used for infrastructures and transport from corrosion extending the life cycle of steel products

• When used for coating steel it contributes to the reduction in CO₂ emissions

The countless areas of use of zinc and its excellent physical properties therefore confirm the great importance that zinc life cycle has for our planet. Here in Bruschi we are proud to use a highly sustainable material, essential for life and for the protection of the riches of our Earth.

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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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