Zinc and Aluminum Die-Cast Components for Airframe™ Exoskeleton

Dynacast's zinc and aluminum die-cast components for the Airframe™ Exoskeleton are a prime example of zinc die casting / aluminum die casting / precision die-cast components for industrial assistive devices. These components were developed for Levitate Technologies' Airframe™ Exoskeleton, a body-worn assistive exoskeleton device that helps reduce muscle fatigue and supports workers in tasks requiring arm elevation, sustained arm positions, or repetitive motions over long periods. Dynacast supported Levitate from the design phase to production, using a combination of zinc die casting to increase strength and aluminum die casting to reduce weight for critical components of the device.
In industrial manufacturing, workers in automotive factories, assembly lines, machine shops, inspection areas, and other production environments often have to work with elevated arms or maintain fixed arm positions for extended periods. This can cause fatigue, reduce efficiency, and affect operational stability. If the assistive device uses unsuitable components, the product may be too heavy, difficult to wear for long periods, have poor durability, non-smooth movement, assembly errors, or be difficult to mass-produce. Therefore, Dynacast's zinc and aluminum die-cast components are a suitable solution for businesses requiring metal components that are lightweight, durable, and precise for industrial exoskeleton devices.

1. Key Features of the Product

The strength of Dynacast's Airframe™ Exoskeleton components lies in their ability to combine two metal materials according to functional requirements: zinc for components requiring high strength and aluminum for components requiring weight reduction.
The product is designed for the shoulder assembly of the Airframe™, which houses complex cassettes and numerous small components tasked with managing load, transmitting force, and supporting movement during user operation.
The components must meet very high requirements for precision, rigidity, durability, and light weight, similar to the sophistication of precision engineering components yet robust enough for daily industrial environments.
Dynacast participated in DFM – Design for Manufacturability sessions, helping Levitate optimize each component so that the product can be stably mass-produced.
The precision die-casting solution enables the Airframe™ to be significantly lighter than competing exoskeleton devices while maintaining the necessary durability and load-bearing capacity. According to Dynacast, the Airframe™ can be manufactured up to 3 times lighter than competing exoskeletons.
The product is suitable for industrial devices requiring a combination of precision mechanics, lightweight materials, load-bearing capacity, and mass production.

2. What Industries is the Product Applied to?

Zinc and aluminum die-cast components for the Airframe™ Exoskeleton are applied in various fields such as:
- Automotive manufacturing: Supports assistive devices for workers on assembly lines, inspection, and overhead operations.
- Mechanical manufacturing industry: Suitable for labor-assistive devices in repetitive tasks.
- Industrial manufacturing: Used for wearable systems that help reduce worker fatigue during prolonged work.
- Medical and rehabilitation equipment industry: Suitable for products requiring lightweight, durable, and precise mechanical frames.
- Personal protective equipment (PPE) industry: Applied in devices that enhance safety, reduce load, and improve working posture.
- Wearable technology industry: Used for smart wearable devices with complex mechanical structures.
- Assistive robotics and exoskeleton industry: Suitable for component assemblies requiring high durability, light weight, and stable movement.
- OEM/ODM manufacturers: Suitable for businesses needing to develop custom-designed metal components.

3. Technology and Product Usage Process

Dynacast zinc and aluminum die-cast components are typically used in processes such as:
- Industrial exoskeleton device development process.
- Component design process for mechanical wearable devices.
- DFM process to optimize components before production.
- Material selection process for zinc and aluminum based on component function.
- Zinc die-casting process for high-strength parts.
- Aluminum die-casting process for weight-reduction parts.
- Process for handling complex tolerances and dimensions.
- Prototype manufacturing process before mass production.
- Assembly process for cassettes within the device's shoulder assembly.
- Component testing process for durability, precision, and operational capability.
The product is used in various positions such as:
- Shoulder assembly of the Airframe™ Exoskeleton.
- Force transmission cassettes in assistive devices.
- Load management components when users lift their arms.
- Components supporting force distribution from the shoulders, neck, and upper back to the core body.
- Small metal frames in wearable devices.
- High-stress components requiring zinc die casting.
- Components requiring weight reduction through aluminum die casting.
- Assembly parts with complex tolerances.
- Mechanical assemblies requiring stable movement in industrial environments.
- Positions requiring lightweight, durable, and precise components in assistive devices.
Regarding usage method, Dynacast zinc and aluminum die-cast components are integrated into the mechanical structure of the Airframe™ Exoskeleton according to Levitate Technologies' engineering design. When selecting similar components, businesses need to clearly define load-bearing function, target weight, assembly position, dimensional tolerances, movement requirements, projected output, and actual usage conditions to ensure the device achieves durability, lightness, and stable operation.

4. Structure and Main Components of the Product

Zinc and aluminum die-cast components for the Airframe™ Exoskeleton are a group of precision metal parts, typically comprising key elements such as:
- Zinc die-cast components for positions requiring high strength and load-bearing capacity.
- Aluminum die-cast components for positions requiring weight reduction.
- Small cassette assemblies in the device's shoulder area.
- Mechanical structures supporting force transmission and load management.
- Components with tight tolerances to ensure precise assembly.
- Component surfaces finished to suit industrial use requirements.
- Small, complex shapes suitable for body-worn devices.
- Structures supporting mass production with consistent quality.
Depending on project requirements, customers can choose appropriate zinc material, aluminum material, wall thickness, component shape, finishing options, tolerance standards, load-bearing positions, and assembly methods. Correct parameter selection helps the device reduce weight, increase durability, improve wearability for extended periods, and enhance operational efficiency in industrial environments.

5. Benefits for Businesses and Factories

The use of Dynacast zinc and aluminum die-cast components helps businesses develop exoskeleton devices that are lighter, more durable, and better suited to actual factory usage needs.
The product helps solve the challenge of balancing durability and weight, which is a critical requirement for all wearable labor-assistive devices. If the device is too heavy, users find it difficult to wear for long periods; if components are too weak, the device cannot ensure safety and operational stability.
For manufacturers of industrial equipment, wearable devices, assistive robots, and exoskeletons, precision die-cast components help optimize design, reduce error risks, increase assembly stability, and support mass production.
In new product development projects, Dynacast's early involvement in the DFM stage helps customers optimize each component before production, thereby reducing technical risks, improving product performance, and shortening the commercialization process.
Furthermore, the product is also suitable for businesses looking to develop new-generation labor-assistive devices, industrial assistive devices, smart wearables, or small mechanical assemblies that need to be lightweight, durable, and precise.
Dynacast's zinc and aluminum die-cast components for the Airframe™ Exoskeleton are a suitable solution for businesses requiring precision metal components, load-bearing zinc die-cast components, lightweight aluminum die-cast components, and industrial exoskeleton manufacturing solutions. The product helps optimize weight, enhance durability, improve wearability for extended periods, supports mass production, and effectively meets the demands of modern industry.