Zinc die casting is a precision manufacturing process widely used at diecasting-mould.com and throughout various industries. This zinc die casting guide covers everything you need to know about designing and producing parts through .

What is Zinc Die Casting?

Zinc die casting involves injecting molten zinc alloy into a steel mold under high pressure. As the metal solidifies and cools inside the mold, it adopts the desired shape with excellent precision and surface finish. Zinc alloys are particularly well-suited for die casting due to their low melting temperature.

Material Properties of Zinc

The most common zinc alloy used in die casting is Zamak-3, with compositions of 95-97% zinc, 0.5-3% aluminum, and 0.05-3% copper. This alloy exhibits the following properties:

• High strength-to-weight ratio
• Good corrosion resistance
• Melting point of 715°F (380°C)
• Fluidity for filling intricate cavities
• Tensile strength of 25-45 ksi (170-310 MPa)

Other available zinc alloys include Zamak-1, 2, 4, 5 for specialized applications.

Design Considerations for Zinc Die Casting

Key factors to consider when designing parts for zinc die casting at diecasting-mould.com include wall thickness, draft angles, ribs, corners, gate locations, and machining allowances.

Wall Thickness

Maintain uniform thickness of 0.04-0.25 inches for optimal filling without defects. Avoid abrupt changes that interrupt metal flow.

Draft Angles

Incorporate draft angles of 3-10° to facilitate ejection from the die. Internal features may require doubled draft.

Ribs and Bosses

Use ribs to reinforce thin walls and complex geometry. Consider draft and impact on cooling when designing ribs.

Corners and Radii

Round sharp corners to at least 0.04 inches to reduce stress concentration and ejection forces.

Gate and Runners

Place gates in low-stress areas away from critical features. Minimize runners and risers to streamline material flow.

Machining Allowance

Account for +/-0.010-0.030 inch machining tolerance based on part complexity, size, and surface finish required.

Advantages of Zinc Die Casting

Key benefits include precision, strength, aesthetic surface finish, versatility, and lower cost when compared to other methods like aluminum die casting.

Applications of Zinc Die Casting

Automotive, hardware, appliances, electronics, medical devices, tools, and household items frequently employ zinc die casting for structural components demanding mechanical strength, dimensional accuracy, and intricate details.

Zinc Die Casting Process at diecasting-mould.com

Our facility offers complete zinc die casting services from engineering and tooling development to high-volume zic die casting products. State-of-the-art presses, automated trim/eject machines and in-house heat treatment ensure process control and precision.