Matech Develops Custom Zinc Alloy Die-Casting Gears for EU Electrical Motor Applications

Matech Industry Ltd. recently completed a customized zinc alloy die-casting gear project for an overseas industrial customer. The gears are designed for electrical motor applications and will be exported to the European Union.

For this project, the customer had requirements not only for the dimensional and manufacturing quality of the gears, but also for compliance with EU RoHS and REACH SVHC regulations. Third-party testing and supporting compliance documents were therefore included in the project requirements.

Project Overview

• Product: Custom zinc alloy die-casting gears
• Application: Electrical motors
• Market: European Union
• Material: Zinc alloy
• Manufacturing Process: Die casting and related finishing processes
• Compliance Requirements: RoHS and REACH SVHC
• Testing: Third-party compliance testing plus MATECH internal quality inspection

Addressing Technical Requirements at the Early Stage

The project involved several technical points that needed to be clarified before mass production.

The customer required customized die-casting gears with specific requirements for die-casting tolerances, draft angle, and surface treatment. Instead of moving directly into production, Matech communicated with the customer during the early stage to identify critical dimensions and clarify the surface-treatment requirements.

There was also some uncertainty regarding surface-treatment terminology. To make sure the final process matched the customer's actual use requirements, Matech confirmed the details directly with the customer and prepared two sets of samples using different surface treatments for better comparison.

This approach allowed both sides to evaluate the available options before finalizing the mass-production process.

Raw Material and Compliance Control

Since the products are intended for the EU market, compliance with RoHS and REACH SVHC requirements was an important part of the project.

Matech selected zinc alloy raw materials that meet the relevant hazardous-substance control requirements and maintained control over the production process to reduce the risk of restricted substances being introduced during manufacturing.

For compliance verification as the customer required, Matech arranged testing through authoritative third-party laboratories. The project required testing related to RoHS 10 restricted substances and 73 REACH SVHC substances.

The corresponding third-party test reports provide supporting documentation for the customer's EU customs clearance and product compliance requirements.

From Sample Verification to Mass Production

Before entering mass production, Matech carried out sample verification with multiple process solutions.

The customer reviewed the two samples and approved the surface finish process after comparison. Once the practical production process had been confirmed, the project moved forward to mass production.

This step was particularly important for a customized die-casting component because the final process needed to take into account not only the product dimensions, but also die-casting feasibility, surface treatment, and compliance requirements.

The customer's approved sample and process verification plan provided a clear basis for subsequent production.

Supporting EU Market Requirements

The completed custom zinc alloy die-casting gears meet the customer's specified RoHS and REACH requirements. The required third-party reports were also obtained to support customs clearance and compliance documentation for the EU market.

According to the project feedback, the gears delivered by Matech have been installed on the motor assembly and were reported to be working well in the EU market.

The customer also gave positive feedback to the Matech team after receiving the goods.

For this project, the focus was not simply on producing a custom die-casting gear. The work also involved process feasibility assessment, technical clarification, sample comparison, raw material control, third-party compliance testing, and document preparation.

About Matech

Matech Industry Ltd. provides customized manufacturing solutions for precision castings, CNC-machined parts, conveyor chains, and other industrial components.