Neway Casting Supply: Philips Electric Shaver Shell Zamak Die Casting and Painting

High-Precision Zamak Die Casting for Personal Care Devices

Zamak alloys are widely used in small appliance enclosures for their excellent fluidity, dimensional stability, and surface finish potential. For the Philips shaver shell, Zamak 5 was selected due to its enhanced strength (tensile strength ~295 MPa) and better plating performance than Zamak 3.

Key casting parameters:

• Wall thickness: 1.5 mm (±0.05 mm) to minimize weight without compromising rigidity

• Die temperature: ~200–250°C to avoid surface flow lines

• Fill time: ≤0.15 seconds for detailed mold replication

• Surface porosity: <0.5% (validated via pressure tightness and dye penetrant testing)

Learn more about zinc die casting processes and their applications in precision consumer hardware.

Mold Design and Surface Control Strategy

The mold design integrates lifter mechanisms and mirror-finish cavity inserts (Ra ≤ 0.8 µm) to support both shape complexity and surface cosmetic quality. Strategically positioned vents and overflow channels ensure gas evacuation, eliminating common defects like cold shuts and swirl marks.

Dimensional tolerances follow ISO 8062-3 Grade CT6 standards, while visual surfaces conform to ISO 1302 N6 finish. Additional polishing and shot peening processes are implemented post-casting to prepare for primer and paint layers.

Explore our tool and die solutions for detailed cosmetic part development.

Painting and Surface Finishing for Premium Feel

Once the die cast shell is finished and cleaned, a multi-layer painting system is applied:

• Primer coat (20–25 µm) for adhesion and corrosion resistance

• Base metallic paint (25–30 µm) in custom-matched Philips color palette

• Clear protective topcoat (15–20 µm) with gloss or matte options

Performance standards:

• Scratch resistance: >2H (pencil hardness)

• Adhesion: ASTM D3359 rating 5B (no peel)

• Salt spray resistance: >720 hours (ASTM B117)

• Thermal cycling: −20°C to 60°C, 100 cycles with no discoloration

The painting process is performed in a Class 1000 cleanroom with robotic spraying arms and infrared curing to guarantee consistency.

Review our painting services and how they elevate product surface aesthetics and durability.

Quality Assurance and Compliance

All production follows ISO 9001:2015 quality management and adheres to RoHS/REACH material compliance. Each batch undergoes:

• CMM inspection for dimensional accuracy

• Coating thickness measurement (eddy current probe)

• Visual inspection under diffused lighting (Class A surface criteria)

• Pull-off adhesion testing (ASTM D4541)

Packaging uses custom EVA foam inserts to protect painted surfaces during logistics, ensuring final products arrive scratch-free and ready for assembly.

Customization for Design Variants and Brand Differentiation

Multiple shell variants were manufactured for regional models featuring different finishes, grip textures, and button placements. These variants used shared die inserts to maintain production efficiency while supporting part differentiation.

Our integrated die casting one-stop service includes engineering support, prototype evaluation, tooling, casting, finishing, and pre-assembly.

FAQs

1. What are the surface finish standards required for consumer electronics housings?

2. Which zinc alloys provide the best balance between strength and aesthetics for shaver shells?

3. How is paint adhesion tested for zinc die cast components?

4. What dimensional tolerances are typically used for cosmetic die cast parts?

5. How are die cast shells protected from scratches during transport and assembly?