The redesigned one-piece magnesium enclosure (right) houses vital components in its application within the projector (left).


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ing casting suppliers for quotation pur- poses. During a phone call after receipt of the drawings, engineers discussed some technical issues for the enclosure, which had been a two-piece casting produced via thixomolding, a process of injection molding of a semi-solid alloy. In exploring possible solutions, the two sides pursued a concept of the housing that would turn the component into a single magnesium die casting. Within a few months, collabora-


tive technical discussions and fl ow analyses were taking place for the one-piece design. Reducing the component to a single casting would reduce part count ratio, improve physical and mechanical properties, simplify inventory management and minimize required machining. “With the original design, not only


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40 | METAL CASTING DESIGN & PURCHASING | Jan/Feb 2015 APPL068 Brand Ad_Modern Casting_4.5x4.875.indd 1 4/23/14 3:02 PM


did you have a two-piece assembly, which is more expensive, but you also had the assembly component to it,” said Eric Voss, Christie advanced product developer. T e two-piece as- sembly also could “result in potential fi nal assembly issues on the produc- tion line.”


By simplifying the assembly into a single diecast component, Christie and its supplier decreased shipping, tooling


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