Our Zinc Die Casting Services

At Yigu Technology, our Zinc Die Casting solutions set the standard for high-quality, cost-effective manufacturing. With unmatched manufacturing expertise, advanced tooling design, and a focus on precision casting, we transform versatile zinc alloys into durable, dimensionally accurate components for automotive, electronics, and consumer goods industries. Whether you need high production volume runs or custom-designed parts, we deliver reliable results—backed by rigorous quality control process and dedicated customer support.

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What Is Zinc Die Casting?

Zinc Die Casting is a specialized metal casting process that uses high pressure to force molten zinc alloy into a steel mold (die), producing complex, high-precision parts. As a core casting technology, it leverages zinc’s unique properties—excellent castability, strength, and affordability—to meet diverse industry needs.

A clear process overview reveals its efficiency: Molten zinc (heated to 380–420°C, far lower than aluminum) undergoes high-pressure injection into a closed die. The metal cools and solidifies rapidly, then the die opens to eject the finished part. Table 1 compares zinc die casting to other die casting process types:

Die Casting Type	Metal Used	Melting Point	Key Benefit	Ideal Use Case
Zinc Die Casting	Zinc Alloys	380–420°C	Low cost, small part precision, fast cycle time	Electronics housings, hardware, automotive small parts
Aluminum Die Casting	Aluminum Alloys	650–750°C	Lightweight + high strength	Automotive structural parts, aerospace components
Magnesium Die Casting	Magnesium Alloys	650–675°C	Ultra-light, high thermal conductivity	Laptop frames, drone parts

Yigu Technology’s Zinc Die Casting Capabilities

Our Zinc Die Casting Capabilities are engineered to handle projects of all scales, from simple hardware to complex, custom components.

Key Capabilities Breakdown

Capability Area	Details
Production Capacity	200,000–1,000,000 units/month (optimized for high-volume electronics/automotive parts)
Precision Casting	Achieves tight tolerances as low as ±0.03mm for small, intricate parts
Custom Casting Solutions	Tailored mold design, alloy selection, and surface treatment for unique project needs
Manufacturing Expertise	18+ years of experience in zinc die casting, with specialized knowledge in hot chamber processes
High-Quality Castings	ISO 9001 certified; 100% post-production inspection (dimensional, surface finish, defect checks)

The Zinc Die Casting Process

The Zinc Die Casting Process follows a streamlined workflow optimized for speed and precision, leveraging zinc’s low melting point to minimize cycle times.

Injection Process: Molten zinc alloy is drawn into a heated gooseneck (in hot chamber machines) and injected into the die cavity at high pressure (30–100 MPa) and speed (1–5 m/s), ensuring full filling of even tiny details.

Cooling Process: The metal solidifies rapidly (5–15 seconds) in the die, maintaining dimensional tolerances while pressure is held to reduce porosity.

Ejection Process: The die opens, and ejector pins push the finished part out—zinc’s low shrinkage rate ensures the part retains its shape.

Trimming Process: Excess material (flash) is removed via automated trimming tools, creating a clean, finished part.

Quality Control Process: Parts undergo inspection for defects, dimensional accuracy, and surface finish before moving to surface treatment or shipping.

On average, the total cycle time for a small zinc part (e.g., an electronics connector) is just 10–20 seconds—faster than most other die casting processes.

Materials Used in Zinc Die Casting

Choosing the right zinc alloys is critical for part performance, and we offer expert material selection support to match your project’s requirements.

Zinc Alloy Types & Properties

Alloy Type	Common Grades	Key Zinc Alloy Properties	Typical Applications
Zamak Alloys	Zamak 3, Zamak 5	High ductility (Zamak 3), improved strength (Zamak 5), excellent castability	Electronics housings, hardware, automotive brackets
Zinc-Aluminum Alloys	ZA-8, ZA-12	Higher strength (up to 300 MPa), better wear resistance	Industrial gears, heavy-duty hardware
Custom Alloys	Blended to specs	Tailored for corrosion resistance, heat tolerance, or conductivity	Medical device components, marine hardware

All our casting materials undergo rigorous testing for material compatibility with molds and surface treatments, ensuring consistent quality.

Surface Treatment for Zinc Die Cast Components

Surface Treatment enhances the durability, aesthetics, and functionality of zinc die cast parts, addressing industry-specific needs from corrosion resistance to branding.

Treatment Method	Purpose	Advantages	Ideal For
Plating	Adds a protective/ decorative metal layer (e.g., nickel, chrome, zinc)	Improves corrosion resistance, conductive, sleek finish	Electrical connectors, automotive trim
Painting	Enhances aesthetics and basic protection	Fast application, low cost, wide color range	Consumer goods, decorative hardware
Coating	Applies a polymer or ceramic layer	Resists scratches, chemicals, and UV damage	Outdoor components, medical devices
Polishing	Creates a smooth, reflective surface	High-end appearance, hides minor imperfections	Luxury goods, architectural hardware
Anodizing	Forms a protective oxide layer (for zinc-aluminum alloys)	Improves wear resistance, customizable colors	High-performance industrial parts
Surface Finishing	General refinement (deburring, sanding)	Ensures smooth edges, consistent texture	All zinc die cast parts, pre-treatment for plating/painting

Tolerances in Zinc Die Casting

Tolerances are a strength of zinc die casting, with precision tolerances achievable thanks to zinc’s low shrinkage and high castability. We adhere to strict tolerance standards to meet even the most demanding specs.

Typical Tolerance Ranges for Zinc Die Casting

Part Feature	Standard Tolerance	Tight Tolerance (Custom)	Tolerance Standards
Part Dimensions (≤50mm)	±0.05mm	±0.03mm	ISO 8062:2018 Class CT5
Hole Positioning	±0.08mm	±0.04mm	DIN EN 13920
Flatness	0.04mm/m	0.02mm/m	IATF 16949

Tolerance control is maintained via precision mold design, real-time process monitoring, and post-production measurement using coordinate measuring machines (CMMs).

Advantages of Zinc Die Casting

The Zinc Die Casting Advantages make it a top choice for industries prioritizing cost, speed, and precision.

Cost-Effective: Zinc’s low melting point reduces energy costs, and its high castability minimizes waste (typically <3% per run)—lowering per-unit costs by 20–30% vs. aluminum die casting for small parts.

High Production Volume: Short cycle times (10–20 seconds) enable mass production of up to 1 million units monthly, ideal for electronics and consumer goods.

Dimensional Accuracy: Zinc’s low shrinkage (0.5–1%) and excellent flow properties ensure consistent dimensional tolerances, reducing the need for secondary machining.

High Strength: Even standard Zamak alloys offer tensile strength up to 280 MPa, suitable for structural parts like automotive brackets.

Smooth Surface Finish: As-cast zinc parts have a smooth surface (Ra 1.6–3.2 μm), eliminating the need for extensive surface finishing for many applications.

Design Flexibility: Zinc flows easily into complex molds, enabling intricate features (thin walls down to 0.5mm, small holes) without defects.

Industry Applications of Zinc Die Casting

Zinc Die Casting Applications span diverse industries, thanks to its versatility, cost-effectiveness, and precision.

Industry	Key Applications	Alloy of Choice	Why Zinc Die Casting?
Electronics Industry	Connector housings, switchgear, sensor casings, smartphone components	Zamak 3, Zamak 5	Precision, cost-effective, fast production
Automotive Industry	Door handles, mirror brackets, ignition components, EV charging port parts	Zamak 5, ZA-8	High strength, dimensional stability
Hardware Industry	Locks, hinges, cabinet pulls, fasteners	Zamak 3, ZA-12	Durable, corrosion-resistant (with plating)
Consumer Goods Industry	Toy parts, kitchen utensil handles, cosmetic packaging	Zamak 3	Smooth finish, low cost, safe for consumer use
Medical Industry	Small instrument components, device housings (non-implant)	Zamak 5 (medical-grade)	Biocompatibility, precision
Aerospace Industry	Small interior components, fasteners	ZA-12	High strength-to-weight ratio, reliability

Manufacturing Techniques for Zinc Die Casting

Our Zinc Die Casting Techniques combine proven methods with innovation to deliver consistent, high-quality parts.

Hot Chamber Die Casting: The primary method for zinc (95% of our zinc projects), it integrates a molten zinc pool into the machine—eliminating metal transfer steps and reducing cycle time by 30% vs. cold chamber.

Cold Chamber Die Casting: Used for high-strength zinc-aluminum alloys (e.g., ZA-12) that require higher melting points, ensuring mold durability.

Tooling Design: We use H13 hot-work steel for molds, engineered to withstand zinc’s low melting point and repeated use (200,000+ cycles). Mold vents and gates are optimized for zinc’s flow properties.

Mold Making: Custom molds are designed using CAD/CAM software, with 3D prototyping available to test designs before full production.

Injection Molding Techniques: Automated injection systems control pressure and speed in real time, ensuring consistent filling and minimizing defects like porosity.

Quality Assurance: Every batch undergoes sampling for tensile strength, dimensional accuracy, and surface finish—with X-ray testing available for critical parts.

Case Studies: Yigu Technology’s Zinc Die Casting Success Stories

Our Zinc Die Casting Case Studies showcase how we solve real-world challenges for clients across industries.

Case Study 1: Electronics Connector Housings

Challenge: A global electronics firm needed 500,000 zinc connector housings monthly, with tight tolerances (±0.04mm) and a smooth surface finish (Ra ≤2.0 μm) for seamless mating with cables.
Solution: Used Zamak 3 alloy in our hot chamber die casting process, with automated trimming and plating (nickel) for conductivity. Implemented real-time pressure monitoring to ensure consistency.
Result: Achieved 99.9% defect-free rate, met production targets 1 week ahead of schedule, and reduced per-unit cost by 22% vs. the client’s previous supplier.

Case Study 2: Automotive Door Handle Components

Challenge: An automotive manufacturer required durable door handle brackets with high strength (≥250 MPa) and corrosion resistance for outdoor use.
Solution: Utilized Zamak 5 alloy with coating (epoxy) for corrosion protection. Designed custom molds to integrate mounting holes, eliminating secondary drilling.

Result: Brackets passed 1,000+ hours of salt spray testing, weighed 15% less than plastic alternatives, and withstood 100,000+ opening/closing cycles without failure.

Why Choose Us for Zinc Die Casting?

When you partner with Yigu Technology for Zinc Die Casting, you gain a trusted collaborator focused on your success. Here’s why clients choose us:

Experience: 18+ years in zinc die casting, with deep expertise in hot chamber die casting (the most efficient method for zinc) and custom alloy formulation.

Quality Assurance: We adhere to ISO 9001 and IATF 16949 standards, with rigorous testing at every stage—from raw material inspection to final part approval.

Customer Service: A dedicated account manager provides 24/7 support, from design consultation to post-delivery follow-up. We offer design for manufacturability (DFM) reviews to optimize your part for cost and performance.

Technical Support: Our engineering team provides on-demand assistance for mold design, alloy selection, and process troubleshooting—ensuring your project stays on track.

Reputation: 95% of our clients return for repeat projects, thanks to our consistent quality, on-time delivery (98% rate), and transparent communication.

Value for Money: We balance cost and quality, offering competitive pricing without compromising on precision casting or high-quality castings.

FAQ for Zinc Die Casting

What’s the difference between Zamak 3 and Zamak 5 zinc alloys?

Zamak 3 is the most common zinc alloy, offering excellent ductility (easy to bend without breaking) and castability—ideal for electronics housings and hardware. Zamak 5 adds copper for improved strength (20–25% higher than Zamak 3) and wear resistance, making it better for automotive parts and structural components. Our team can help you choose based on your part’s load and usage.

Can zinc die casting be used for parts that need corrosion resistance?

Yes. While raw zinc is prone to corrosion, surface treatment (e.g., plating, coating, or chromate conversion) provides long-lasting protection. For example, nickel-plated zinc parts can withstand 1,000+ hours of salt spray testing—suitable for outdoor automotive or marine applications. We also offer corrosion-resistant alloys like ZA-8 for harsh environments.

Is zinc die casting suitable for small-batch production, or only high volume?

While zinc die casting excels at high production volume, we also support small-batch orders (1,000–10,000 units). Our modular tooling design reduces upfront mold costs for small runs, and we offer shared production schedules to keep pricing competitive. For prototypes, we can use 3D-printed molds to deliver samples in as little as 5 days.