. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design Details
Metal Superior to Plastic for Handheld Translator Jiten Shah, Product Development & Analysis, Naperville, Illinois CASTING PROFILE
Casting Process: Graphite diecasting. Material: A380
aluminum-silicon-copper alloy. Weight: 0.5 lbs. Dimensions: 6.68 x 3.8 x 0.85 in. Application: Military, law enforce- ment and emergency services. Design Goals: Thin walled, highly complex near-net-shaped casting with cosmetic finish.
U
sing its graphite diecasting process, Armstrong Mold Corp., East Syracuse, N.Y., produced the prototypes and marketing versions of a handheld translator housing for use in the military and emergency services. Thin-
wall cast features and near-net-shape geometry reduced secondary machining operations and overall cost. The surface finish of the cast assembly enabled the initial production parts to be used for display purposes.
The casting process enabled the assembly to meet strict mechanical and thermal requirements. • Stiffeners and as-cast posts served as mounting locations for as- sembling the two halves of the housing.
• Metal conducts more heat due to its high thermal conductivity compared to engineered plastic, providing better thermal manage- ment of the assembled handheld translator and extending the life of the complex electronic sub-components the device houses.
• Metal castings are ductile and absorb more impact energy than plastic parts, avoiding failures. Additionally, the casting provided better radio frequency and electromagnetic interference shielding.
• The metal casting, with stiffeners and strategically positioned ribs, provided excellent mechanical strength and allowed the part to withstand the impact of being dropped.
22 Metal Casting Design & PurChasing
May/June 2010
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