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An OEM for a headlight subassembly was looking for an alternative to plastic for daytime running lamp and turn signal mounts. Diecast aluminum was chosen over plastic for its heat sink characteristics, which would conduct heat away from the LED bulbs. Aluminum also allowed for consistent dimensions at the bulb mounting surfaces, which were required to be parallel. The assembly also required tight tolerances for the lens hole position, which provided wiring access for the bulbs. The part needed a rigid material to hold up to component assembly and mounting.
--By Jiten Shah, president of Product Development & Analysis (PDA) LLC, Naperville, Ill., and a 25-year casting design and manufacturing veteran.
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