The Precision Champion: Zinc Die Casting

If Aluminum is the “all-rounder” of the casting world, Zinc is the “specialist” in precision and surface perfection. When you hold a heavy, high-quality chrome faucet or a complex, tiny gear inside a lock, you are likely feeling the weight and strength of a Zinc alloy.

Zinc’s “secret weapon” is its low melting point. Because it melts at much lower temperatures than aluminum or steel, it flows like water, allowing us to cast parts with razor-sharp details and walls as thin as a business card. Even better? The lower heat means our steel molds last up to 10 times longer—often producing over a million parts before needing replacement.

The “Zamak” Family: Which one do you need?

Most industrial zinc casting revolves around the Zamak series. Each blend is designed for a specific balance of ductility and strength.

The “Net Shape” Advantage

Zinc is the king of “Net Shape” manufacturing. This means that when the part comes out of the mold, it is so precise that it usually requires zero secondary machining.

• Precision: We can hold tolerances within microns.

• Thin Walls: Zinc can be cast with walls thinner than 1mm without losing structural integrity.

• Easy Assembly: Zinc is very “ductile,” meaning we can design parts that can be “staked” or “crimped” during assembly without the metal snapping.

The King of Surface Finishes

One of the biggest reasons designers choose Zinc over Aluminum or Plastic is its aesthetic versatility. Because Zinc is a very “clean” metal with low porosity, it takes surface treatments better than almost any other material:

1. Chrome Plating: Achieve that mirror-like, high-end “luxury” finish seen in jewelry and bathroom fixtures.

2. Electroplating: Whether it’s gold, silver, or nickel, Zinc provides the perfect base.

3. Physical Vapor Deposition (PVD): For ultra-hard, scratch-resistant coatings in various colors.

Did You Know? Zinc is a “Hot Chamber” process. The injection mechanism is submerged in the molten metal, allowing for incredibly fast cycle times (up to 1,000 shots per hour). This makes Zinc one of the most cost-effective solutions for high-volume, high-precision small parts.

Does your part require a premium “heavy” feel or a mirror-finish chrome coating? Let’s chat about your assembly—Zinc might allow us to combine five separate components into one single, complex casting.