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Re:Aggressive design caused Samsung Galaxy Note 7 battery ex... by burfog on Saturday December 03, 2016 @12:37AM (#13094512)
What about forging? Rough out the shape from AlZnMgCu1,5 (EN AW-7075) alloy, heat to 450°C, and slam it between a pair of dies.

Compared to cast or machined parts, you get a 20% higher strength-to-weight ratio from the forging. The cycle time is decent I think, perhaps 3 per second with a 0.06 second contact time in the dies.

Re:Aggressive design caused Samsung Galaxy Note 7 battery ex... by mritun on Saturday December 03, 2016 @12:45PM (#13096609)
Tolerances are poor with forging.