PHB offers a wide range of services to facilitate aluminum and zinc die-cast product development & design from start to finish with a focus on efficiency and quality. Our large-scale diecast manufacturing capabilities offer global OEMs quick turnaround times, quality control, customization options, and in-house reliability from beginning to end.

Since our start more than a century ago, we have grown to operate in a massive facility with more than 750,000 square feet of floor space and approximately 500 dedicated employees. That kind of size and experience offers reliable results throughout the entire development process, even for large Fortune 500 companies. At PHB, we act as a partner throughout the entire development and design endeavor.

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Development and Prototyping

Our elite engineering and manufacturing team works alongside our estimating and account management teams to offer efficient solutions specifically designed to maximize quality and return on investment. From the earliest stages, our multiple teams are involved to ensure not only manufacturability but also multi-cavitation design and metal program solutions. In doing so, we have established a record of reducing costs on both existing and next-generation programs.

Technological growth is the key to success in today’s world, and we have committed the necessary resources to remain an industry leader including high-end machinery like robotics, laser measurement, and computer imaging. Using these advanced tools alongside the labor of experienced and dedicated toolmakers, our team offers reliable speed to market with the management of tool & die programs.

Our Services

As a full-service partner, we offer a wide range of solutions to businesses including OEMs in the automotive, aerospace, or consumer products sectors in addition to others.

Aluminum Die Casting

Our aluminum die casting facility houses 58 presses with a size range from 250 tons to 2000 tons for both low and high-volume production programs. Our process is supported by press-side imaging, robotics, and tool maintenance programs to ensure quality and accuracy while extending the life of our tools and reducing cycle times to keep costs low.

Zinc Die Casting

Our zinc die casting capabilities can produce zinc alloy components for low and high-volume production programs across 58 presses. We are a global leader in zinc die casting with highly trained metallurgists who have experience working with zinc alloys Zamak 3, 5, and 7 in addition to zinc-aluminum alloys ZA-8, ZA-12, and ZA-27.

CNC Machining

PHB offers close-tolerance CNC machining services in turning, milling, drilling, boring, and tapping, alongside assembly and leak test-verified impregnation. We have 10 CNC lathes, 27 CNC horizontal machine centers, and 12 vertical machine centers capable of handling spindle speeds of up to 18,000 rpm. They are additionally equipped with high-pressure coolant and 4th axis capabilities, allowing for the manufacturing of parts up to 36” in diameter.

Tool & Die

Tool & die services from PHB cover all aspects of the design and production process with a 100 to 2000-ton construction capacity. Our team can additionally carry out die-cast mold revision, mold and die repair, and tool validation. Through our engineering and metal flow analysis, we are able to limit costs without sacrificing quality by making use of technology like AutoCAD, Pro Engineer/CREO, and MAGMAsoft® flow.

Achieving Cost-Effective Products

Since PHB offers multiple solutions across the entire design process, we are able to achieve greater levels of cost-effectiveness across our range of services. Strict customer requirements can be met all while reducing costs significantly thanks to our engineering and development capabilities working alongside our prototyping services. Augment this with computer-aided simulations, and costs tend to decrease significantly alongside development time without sacrificing productivity and quality.

Reducing overall costs is one of the most influential benefits of partnering with a full-service supplier. Not only will costs for customers remain consistent throughout the process, but there are more opportunities to reduce those costs when a singular source is managing the entire design and manufacturing effort. The end goal of our efficient prototyping and early involvement is to produce reliable high-quality molds and end products in a turn-key die casting process all while taking advantage of our advanced technology like AutoCAD and MAGMAsoft® to reduce overall costs and maximize quality.

Full Process Quality Control

From beginning to end, PHB utilizes precision quality control standards to oversee the entire process. Our assembly and impregnation processes are verified through our leak test capability and implemented using Imprex 95-1000A resin. Our leak testing capabilities are available as a value-added service applicable to a large range of sizes and materials, and it’s all carried out in-house. Our test equipment is manufactured by Cincinnati Test Systems and Testra/Unson.

Additionally, our Coordinate Measuring Machines allow us to rapidly identify and map all characteristics of any given product to ensure quality reverse engineering and 3D scanning as needed. Through x-ray, spectrometry, particle inspection, vacuum decay and mass flow testing, and vision inspection with thermal imaging, PHB maintains quality control from beginning to end. Whether you need mold design testing, prototyping, component manufacturing, finishing, packaging, or all of the above, our quality control standards are consistent throughout.

PHB Die Cast Product Development & Design for Large OEMS

At PHB, we have established long-standing relationships with large OEM manufacturers, including one of the largest engine component manufacturers in the world. What started as one or two parts has since evolved into regularly producing more than 200 parts for them. With PHB as their trusted partner, they continue to find success in the industry, and your business can, too.

The automotive industry rapidly changes and advances, and our produced parts must reflect that. Our continuous improvement and innovation efforts have allowed us to create new singular parts made from multiple components fused, increasing both performance and efficiency in the manufacturing process. By utilizing our design, machining, and testing services, our large OEM partners can foster success and growth in the industry.

Room for Customization

As companies grow larger, they tend to need a wide variety of die-cast solutions for their customers. By partnering with a manufacturer and developer like PHB, companies can take advantage of numerous customization options for die mold casting that are compatible with an extensive list of materials and design requirements.

At PHB, we have experience in die-cast and injection mold manufacturing using the following materials and can help you find the ideal specialty material for your project.

• Aluminum
• Zinc
• Rubber
• Plastics

Direct Collaboration

Extensive customization is only possible with direct collaboration with the die-casting supplier. At PHB, our team will work with you every step of the way to find the most cost-effective solutions for customizing our services to meet your unique needs. Our teams can oversee the entire design process from material selection to manufacturing the actual casting itself, followed by any necessary treatments. The final phase considers packaging and transport. We will work alongside you every step of the way to optimize our services to strictly abide by your requirements.

Why Choose PHB

At PHB, we have more than 100 years of experience designing and manufacturing die-cast molds for a wide range of industries. In our history, we have solved problems that require a high level of intricate details, such as complex automotive lighting and multiple cavity castings for pressure die casting. We have additionally worked extensively with large die-casting molds, which are particularly useful for industries that manufacture exceptionally large-size parts. In the past year alone, we produced 15,848,693 castings and poured 48,501,698 pounds of alloy, and we are ITAR registered and IATF certified, encompassing ISO 9001.

By partnering with us throughout the process, businesses can experience a commitment to quality, as all our multiple teams work together to find cost-efficient solutions while maintaining premium quality performance. With turn-key solutions, large businesses can benefit from using our shop as a singular source throughout the entire development and design process from start to finish. Request a quote from our team today to get started.

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