How can die casting reduce assembly steps in complex medical devices?

Integration Through Net-Shape Manufacturing

Die casting enables net-shape or near-net-shape production, allowing multiple features of a medical device to be consolidated into a single component. By eliminating the need for secondary joining or fastening, medical enclosures, instrument frames, or structural subassemblies can be cast with integral bosses, threads, clips, ribs, and cable channels—significantly reducing the number of separate parts and subsequent assembly steps.

Neway leverages alloys such as A360 and ADC12, both of which provide excellent fluidity and precision for complex geometries required in advanced medical devices.

Consolidated Functional Features

Die casting allows complex medical device components to incorporate:

• Snap-fit features or hinge mechanisms

• Integrated mounting points for PCBs or sensors

• EMI shielding walls and guide rails for internal components

• Sealing grooves or gaskets for water-resistant medical housings

These features would typically require separate machining, welding, or fastening operations if not integrated into the casting.

Elimination of Sub-Assemblies

Through precise tool and die making, a die cast part can replace what might otherwise be a multi-component assembly. For example, a handheld diagnostic device housing may be cast in one piece with internal supports, battery compartments, and external mounting brackets—all produced in a single shot.

This reduces:

• Labor and time required for manual assembly

• Error risks from misalignment or incorrect fit

• Overall part weight and bill of materials

Improved Assembly Efficiency and Quality

Integrating features into one casting not only cuts assembly time but also improves quality through:

• Tighter dimensional tolerances

• Better part-to-part consistency

• Fewer fasteners and adhesives

• Reduced post-assembly inspection requirements

Neway’s high-precision aluminum die casting combined with CNC post-machining ensures critical interfaces are accurate, clean, and assembly-ready.

Neway’s Support for Streamlined Medical Device Manufacturing

Neway helps OEMs reduce device complexity and production cost by offering:

• Integrated aluminum die casting for housing and structural parts

• Custom tool and die design with built-in features to eliminate secondary operations

• Full-service assembling for pre-configured subcomponents

• DFM support through design engineering to optimize integration from the outset