Pittsburgh-based DynaVox Mayer-Johnson used using a blend of polycarbonate and ABS for the housings of some of the early designs of its speech communication devices. The company’s design and production partner, Phillips Plastics of Hudson, WI, recommended it consider cases made with the thixomolding process, in which liquid magnesium is molded.
“The magnesium moldings have thin walls and their strength-to-weight ratio is astronomical,” says Rick Severa, director of product design at DynaVox Mayer-Johnson. In addition to their thin walls, another advantage of using magnesium is that entire housing becomes a big heat sink.
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