Electric tool hardware solutions

Die casting solutions for power tool hardware

The core requirements for power tool structural components are high strength, lightweight design, heat dissipation, and durability. Die casting (especially aluminum alloy and magnesium alloy die casting) perfectly meets these needs. Below are die casting solutions and key technical points for power tool hardware.

1. Core Application Components

(1) Tool Housing

Motor Housing (Aluminum alloy die casting, heat dissipation + electromagnetic shielding)

Handle Housing (Magnesium alloy die casting, weight reduction + shock resistance)

Gearbox Housing (High-strength aluminum die casting, impact resistant)

(2) Internal Structural Components

Transmission Gear (Zinc alloy die casting, high precision + wear resistance)

Heat Sink (High thermal conductivity aluminum alloy, integrated die casting)

Battery Compartment (Die-cast aluminum + fire-retardant design)

(3) Accessory Components

Quick-change Chuck (Zinc alloy die casting, wear-resistant)

Chuck Assembly (High-strength aluminum die casting, high torque capacity)

Protective Cover (Ultra-thin aluminum die casting, lightweight)

2. Material Selection Scheme

3. Key Process Innovations

(1) High-strength thin-walled die casting (1.2-2.0 mm)

Optimize mold flow channel design to achieve Lightweight handheld tool housings

Case: Electric drill handle uses 1.5 mm magnesium alloy die casting, reducing weight by 25%

(2) Insert Die Casting Technology

Metal + plastic composite: Handle anti-slip area embedded plastic

Metal + ceramic composite: High wear parts embedded zirconia

(3) Vacuum Die Casting Application

Solve motor housing Pore problems , improve heat dissipation efficiency

Improved gearbox density, extended service life

(4) Semi-solid Die Casting (SSM)

Used for High-precision gear parts , reduce machining processes

Surface finish Ra ≤ 0.8 μm, direct assembly

4. Surface Treatment Scheme

5. Industry Pain Point Solutions

6. Leading Application Cases

Bosch Professional Rotary Hammer: Uses a magnesium alloy main frame, reducing weight by 28% while maintaining strength

Makita Brushless Angle Grinder: Integrated die-cast aluminum housing, heat dissipation performance improved by 40%

DeWalt Battery Pack: Die-cast aluminum fireproof structure, UL2054 certified

Hilti Demolition Machine: High-strength aluminum gearbox, impact life up to 500,000 times

7. Future Development Trends

More intelligent integration: Sensors embedded in die castings (such as temperature/vibration monitoring)

More environmentally friendly processes: Bio-based release agents + recycled aluminum application

Stronger materials: Research and development of nano-enhanced aluminum matrix composites

More precise manufacturing: Application of 3D printed conformal cooling molds

Implementation Suggestions

Handheld tools Prioritize the use of magnesium alloy (weight reduction) or high-strength aluminum (impact resistance)

High-heat generating components Must use vacuum die casting + high thermal conductivity aluminum

Moving parts Zinc alloy die casting + special coating is recommended

Appearance parts In-mold decoration (IMD) die casting integrated molding can be used