Aluminum Die-Cast Housing

The Federal Group was approached by a customer who was looking to die-cast parts and then use the parts “as cast” with no additional machining, resulting in a piece that fit together tightly and would be leak free upon assembly.

Thanks to our expertise in aluminum die casting services, our team determined that the parts, if designed according to intent, may have issues regarding casting tolerance and measurement in the future. Knowing that, our experts compiled a list of suggestions that you can find toward the end of this report.

Challenges

Applying design for manufacturing principles, our team identified several key factors to ensure success. Among them, the fact that the part would need to be overmolded in order to hold electrical connections in place.

To inject the overmolding, our experts determined that the high tolerance areas within the piece would need to be sealed off, and that it would need to be done in a way that not only allowed the pieces to fit together, but also be measured, with precision.

Analysis

After identifying the challenges, our team began to identify how we might overcome them. Understanding that the standard tolerance for an aluminum casting of the part was CT6, our team determined that the tolerance was outside most of the critical tolerances designed for the part.

As a result, our team began to explore how including interior draft in the drawing and design of the part may solve for differences in tolerance. Upon further analysis, it also became clear that the overmold tooling – which needed to seal completely upon injection – should not be made until the part drawing and changes were completed.

Solutions

After analyzing the challenges and collaborating with the client, our team reached a number of conclusions regarding the machining, tooling and overall production of the part. Firstly, it became clear that the sealing surfaces, as well as the mating parts where the surfaces join, will have to be machined to the specified tolerance.

Secondly, our experts suggested that the part also be redesigned to allow for draft in the interior walls so that the part may be released from the die, and then have the draft be machined in order to bring the walls into tolerance for overmold tooling.

Finally, as expected, issues arose when measuring the parts due to set-up of the parts and datum. To solve the problem, our team measured with the CMM and verified the dimensions through 3D scanning.

Conclusion

This project demonstrates The Federal Group’s expertise as a leading die casting company with a strong focus on design for manufacturing principles. By identifying potential tolerance and measurement challenges early in the process, our team provided strategic design recommendations that ensured precision, reliability, and production efficiency.

Through our proactive engineering approach, The Federal Group delivered a high-performing, leak-free component that met the customer’s exact specifications.

     Excellent  
     Based on 12 reviews 
    
 
 
   
 
 
        
   Jonathon Lanham 
 2025-09-26
 
 
 Trustindex verifies that the original source of the review is Google. Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!
  
 
       
   Sean Brockhouse 
 2025-04-20
 
 
 Trustindex verifies that the original source of the review is Google. Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines.  Outstanding customer service!!
  
 
       
   Melissa Quiroz 
 2024-08-09
 
 
 Trustindex verifies that the original source of the review is Google. Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!
  
 
       
   Alex Armstrong 
 2023-12-15
 
 
 Trustindex verifies that the original source of the review is Google. Steve was great to work with and was always available when needed.
  
 
       
   Jon Ramsey 
 2023-10-07
 
 
 Trustindex verifies that the original source of the review is Google. Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success.

Would recommend and I plan to use them for future projects.

Thanks again Mike and TFG team.
  
 
       
   Nic Robinson 
 2023-10-05
 
 
 Trustindex verifies that the original source of the review is Google. Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.
  
 
       
   Sean Connelly 
 2023-06-21
 
 
 Trustindex verifies that the original source of the review is Google. The Federal Group was great to work with. Steve was very professional and diligent in providing good advice/feedback as well as following up with me. Look forward to working with them in the future as well!
  
 
       
   Sher Stahl 
 2020-07-10
 
 
 Trustindex verifies that the original source of the review is Google. The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.
  
 
       
   Marshall 
 2020-06-30
 
 
 Trustindex verifies that the original source of the review is Google. Excellent customer service and products!

Talk To An Expert

Our team is ready to help.

Get A Quote