One-Stop Precision Metal Manufacturing from Mold to Delivery

Custom Aluminum and Zinc Alloy Housings for an Italian Industrial Equipment Maker

2026-09-24

The Project

An Italian industrial equipment manufacturer was developing a new line of machinery and needed customized housings to protect internal components while maintaining a professional, durable exterior. The project required both aluminum and zinc alloy parts across different housing sizes and functions—some for larger structural enclosures, others for smaller precision covers and control panels. The client was not looking for off-the-shelf boxes; they needed housings shaped to their exact internal layout, with specific mounting points, connector cutouts, and surface requirements that matched their equipment design.

The Challenge

The project presented three clear requirements that had to hold true across the entire housing family.

Complex structure. The housings included thin-wall sections for weight control, internal ribs for mounting circuit boards and hardware, and intricate outer profiles with integrated flanges and fastening points. Standard extruded or sheet metal boxes could not achieve the geometry the client needed.

High precision. Mating surfaces, sealing edges, and threaded mounting holes had to be accurate enough for clean assembly. In industrial environments, loose tolerances lead to gaps, vibration noise, and premature seal failure—none of which were acceptable.

Stable production. This was not a prototype exercise. The client needed thousands of units delivered consistently, with uniform surface quality, repeatable dimensions, and reliable mechanical performance batch after batch. Any variation would disrupt their assembly line and create warranty exposure in the field.

Our Approach

We treated this as a full manufacturing partnership rather than a simple parts order, managing the project from tooling through to finished delivery.

OEM/ODM engineering support. We reviewed the client’s housing designs and proposed practical adjustments to improve manufacturability—optimizing wall thickness transitions, adding draft angles where needed, and ensuring machining access to critical surfaces. These changes preserved the design intent while making the parts easier to produce consistently at volume.

Mold development. We developed the die casting tooling in-house for both aluminum and zinc alloy variants. Having direct control over mold design and maintenance allowed us to fine-tune the tooling early and keep production stable over the long run.

Die casting. Aluminum die casting was used for the larger structural housings where strength and heat dissipation mattered. Zinc die casting was used for smaller, more intricate covers where surface detail and precision were priorities. Both processes were optimized to minimize porosity and maintain dimensional stability.

CNC machining. After casting, we precision-machined mounting faces, threaded holes, sealing surfaces, and connector openings to ensure every housing assembled cleanly with the client’s internal components. This hybrid approach delivered complex cast geometry where possible and precision machining where necessary.

Quality assurance. We inspected critical dimensions at multiple stages—after casting and again after machining—to catch any drift before it became a batch problem. Surface quality and cosmetic appearance were also monitored to ensure consistency across aluminum and zinc parts.

The Result

The housing family moved from first article approval into full production without major tooling changes or process issues.

Successful product launch. The housings arrived on schedule and met the client’s assembly and cosmetic standards, supporting their new equipment line debut without component-related delays.
Stable mass production. Dimensional consistency, surface quality, and mechanical performance held steady across multiple production releases. The client reduced incoming inspection overhead and moved parts straight into assembly.
Long-term supply partnership. The reliability of the manufacturing process and the consistency of delivery led to an ongoing supply arrangement. The client continues to order these housings as their equipment line grows, with new variants added under the same manufacturing framework.

What This Means for Your Project

If you are developing industrial equipment and need custom aluminum or zinc alloy housings that combine complex geometry, precision machining, and stable mass production—we can manage the full cycle. From mold development to CNC finishing and quality assurance, we deliver housings that protect your internals and present a finished, professional appearance.

Need custom die cast housings for your industrial equipment? Send us your drawings and we will review the design for manufacturability within 24 hours.

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Get in touch with us

Longwin Metal, founded in 2002 as Xiamen Zhenyuan Die Casting Factory, is now an integrated ODM/OEM manufacturer of precision aluminum and zinc die cast components based in Zhangzhou, Fujian.

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Contact: Paul Hu

Phone: +86 13950196086

Email: phu@longwin-metal.com

WhatsApp: +86 13950196086

Address: No. 18-1, Fu Zhao Road, Chen Xiang Town, Chang Tai District, Zhang Zhou City, Fujian Province, China