Part of the Thomas Dudley Group

Increasing Perceived Product Quality

Small changes in component design, manufacturing and finishing can significantly impact upon the perceived quality of an OEM product or appliance. The surprising thing here too is that unit costs need not necessarily increase if materials and other efficiencies are explored.


Component Weight

Perceived quality can increase with component weight. Handles, levers, rails, knobs and other parts that are touched or activated by an end user can be made from heavier materials to convey the impression of strength, solidity and quality.

Zinc for example is nearly two times heavier than aluminium and can be used to manufacture highly intricate components.

MaterialDensity (Kg PER CUBIC METRE)
Magnesium1,738
Aluminum2,712
Titanium4,500
Zinc7,135
Stainless Steel7,480 – 8,000
Iron7,850
Brass (casting)8,400 – 8,700
Copper8,940

Component surface

Zinc die castings ave an extremely responsive surface that allows the adherence of a multitude of finishes. The much lower melting point compared with other materials creates a diecasting surface that is unpitted and one that can be very easily polished and plated, allowing a perfect finish to be quickly and cost-effectively achieved.

MELTING POINTS
MATERIALDEGREES CDEGREES F
Zinc419.5787
Magnesium6501200
Aluminium6601220
Yellow Brass9301710
Grey Cast Iron1127 -12042060 – 2200

Component consistency

Where multiple components such as handles and valves may appear next to each other on a finished OEM product, it is essential to optimise component consistency. Materials such as zinc have excellent fluidity when molten which helps to ensure good in tool flow. As a result, component consistency and ultimately quality can be maintained.