Neway Casting Supply: Philips Electric Shaver Shell Zamak Die Casting and Painting
Personal grooming products require components that combine aesthetics, comfort, and precision. For electric shaver housings, metal casting delivers durability and visual appeal, while precision surface finishing enhances consumer perception and corrosion resistance.
This project highlights the manufacturing of Zamak-based electric shaver shells with complex geometries and cosmetic-grade finishes. It includes tooling, casting, painting, and quality control processes tailored for high-volume consumer product delivery.
Zamak 5 Die Casting for Cosmetic-Grade Enclosures
Zamak 5 was chosen for this application due to its dimensional stability, excellent castability, and plating performance. Its superior strength-to-weight ratio also supports user ergonomics and part longevity.
Material properties (Zamak 5, per ASTM B86):
Ultimate tensile strength: ~295 MPa
Elongation at break: 7.5%
Brinell hardness: 82 HB
Casting tolerance: ISO 8062 CT5–CT6
Surface smoothness (as-cast): Ra ≤ 3.2 µm
Learn more about zinc die casting for cosmetic parts and how it supports precision surface replication and brand-driven design.
Tooling Design for High Detail Replication
The shaver shell required multi-plane geometry, with internal assembly features, and a Class-A external surface. Tooling was designed with high-polish cavity inserts, micro-venting, and balanced gating to minimize flow lines and cold shuts.
Tooling specifications:
Die steel: H13, nitrided and polished
Mold shot life: >100,000 cycles
Cavity surface finish: Ra ≤ 0.4 µm
Fill time: ≤0.2 s using high-speed injection
Review our tool and die making capabilities optimized for high-gloss, customer-facing product shells.
Surface Finishing: Painting vs. Plating
After casting and polishing, the shell surface was coated using an automated painting line for cosmetic electronics parts. A multi-layer system was applied, including primer, basecoat, and topcoat.
Surface Finish Comparison Table
Property | Painted Finish | Electroplated Finish |
|---|---|---|
Typical Thickness | 40–60 µm | 5–10 µm |
Surface Hardness | 2H (pencil) | ~400 HV (nickel/chrome) |
Visual Uniformity | Excellent (matte/gloss) | Mirror gloss (plated) |
Corrosion Resistance | >720 hrs salt spray | >240 hrs salt spray |
Custom Color Flexibility | High | Moderate |
Painting was selected for this project to allow greater color options and tactile control. Our post-process painting line delivers finishes suitable for Class-A consumer surfaces.
Post-Processing and Quality Control
Before painting, parts were cleaned in ultrasonic degreasing tanks and inspected for surface porosity and cosmetic defects. Post-finishing, components underwent visual inspection and adhesion testing.
Key QA parameters:
Coating adhesion (ASTM D3359): 5B rating
Salt spray resistance (ASTM B117): ≥720 hrs
Surface gloss level (ISO 2813): customized per product model
Functional dimensional tolerance: ±0.05 mm after coating
Explore how our post-process QA procedures ensure durable, aesthetically consistent finishes.
Assembly Readiness and Final Packaging
Components were delivered in customer-specific ESD-safe trays, pre-counted and sealed for direct assembly line usage. Optional services include part labeling, protective film application, and mechanical pre-assembly.
Our one-stop supply solution ensures end-to-end manufacturing and handling consistency for high-volume personal care components.
FAQs
What makes Zamak 5 suitable for decorative shaver housings?
How does painted surface performance compare with plated zinc parts?
What surface standards are used for Class-A cosmetic shells?
How are high-gloss finishes maintained across large production runs?
What quality checks are critical for coated die cast cosmetic enclosures?
