Zinc Die Casting

Zinc die casting is used to manufacture metal parts for a wide range of applications. Die casting offers an ideal method for producing sturdy parts with a long service life within reasonably short production windows. Zinc alloys are some of the easiest metals to die cast and offer superior strength-to-weight ratios over many other die casting metals.

At DyCast Specialties Corp., we excel at producing zinc die cast components. As a hands-on, family-owned company, we have always provided our customers with a one-on-one relationship and a willingness to go that extra mile. Our responsive, personalized service and support sets DyCast Specialties apart from our competitors. That’s how we’ve done business since the beginning.

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The Many Benefits of Zinc

Die casting with zinc alloys offers numerous benefits over other types of metals, including:

  • Great corrosion resistance. Zinc is highly resistant to corrosion, making it ideal for use in corrosive environments.
  • Easily plated. The reliable adhesion offered by zinc makes it well-suited for finishing processes such as plating, painting, and powder coating.
  • Excellent conductivity. Zinc features improved thermal and electrical conductivity over many other metals.
  • Better castability when compared to aluminum. Because zinc allows for less draft and thinner walls than aluminum, it offers better overall castability.
  • Complex shapes with thinner walls. Zinc forms parts with complex shapes and thinner walls than aluminum and other metals.
  • Recyclable. Zinc castings are 100% recyclable, making zinc a preferred material for eco-friendly die casting.
  • Superior finishing characteristics. Zinc allows for high-quality finishing, including maximum aesthetic appeal.
  • Longer die life with minimal maintenance. Zinc alloys cause minimal wear on the die during the casting process, facilitating a longer overall service life for the die.
  • Excellent RFI/EMI shielding capabilities. Net-shaped zinc housings and thinner walls provide superior shielding properties.
  • Superior mechanical & physical properties. Die cast zinc offers excellent tensile strength and dimensional stability.

There are various types of zinc alloys suitable for die casting. These alloys are typically divided into two categories: hybrid and standard.

  • Hydrid Alloys
    Hybrid alloys contain more aluminum, which makes them suitable for applications requiring additional strength and increased creep resistance. These alloys include:

    • ZA-8. ZA-8 contains approximately 8.4% aluminum.

    • ZA-27. This type of zinc aluminum alloy contains approximately 27% aluminum.

  • Standard Alloys
    Standard alloys encompass three primary alloys to suit varying design requirements. These alloys include:

    • Zamak #3 (Zinc Alloy 3) is the type of zinc most frequently used in North America for die casting and is considered the industry standard.

    • Zamak #5 (Zinc Alloy 5) is the preferred zinc alloy for most die casting applications in Europe. With a higher copper content than Zamak #3, Zamak #5 features added strength at the cost of reduced ductility.

    • Zamak #7 (Zinc Alloy 7) is a type of modified Zamak 3, with lower magnesium content and more restrictive impurity specifications, allowing for improved ductility, fluidity, and surface finishing.

Applications of Zinc Die Casts

Zinc die cast parts are used for many applications across a wide range of industries, including:

  • Appliances
  • Automotive
  • Connectivity
  • Data communications
  • Electronics
  • Hand tools
  • Handheld communication devices
  • Hardware (fasteners)
  • Medical and healthcare
  • Military
  • Recreational (interior/exterior parts)
  • Retail scanning
  • Robotic automation
  • Telecommunications
  • Video conferencing

Quality Zinc Die Castings from DyCast Specialties

Zinc die casting remains one of the most dependable solutions to manufacture high volumes of parts with short lead times. As one of the most reliable zinc die casting manufacturers, DyCast Specialties can produce durable, long-lasting parts for nearly any application. We can work with both standard and hybrid die cast alloys and will also handle tooling construction from premium H-13 tool steel.

To see how our zinc die casting capabilities can meet your specifications, contact us today or request a quote.

DyCast Specialties Corporation has been providing our customers with the very best in excellence in zinc die castings.

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Specifications

Die Cast Alloys

Zinc – Hvbrid: ZA-8, ZA-27
Zinc – Std: Zamak #3, Zamak #5, Zamak #7

Die Cast Cells

Zinc - Hiqh Pressure

(3) – 187 Ton Zinc Hot Chamber
(1) – 125 Ton Zinc Hot Chamber
(4) – 7 Ton Zinc Hot Chamber

Tolerance

+/- 0.001

Maximum Weight

4.5 Pound

Tooling Construction

All molds are constructed from Premium H-13 tool steel and are heat treated to 46-48 R/C.
Tooling, molds & dies are produced through Dycast Specialties’ in-house tooling department, out-sourced tooling vendors, and overseas vendors.

Mold Longevity

Up to 1,500,000 shots

Tooling concept

10″ x 12″ Standard DME Unit Dies
12″ x 15″ Standard DME Unit Dies
2″ x 2″ House Insert Sets
3″ x 4.5″ House Insert Sets

4.5″ x 7″ House Insert Sets
8″ x 10″ Standard DME Unit Dies
Standard Cavity Retainer Sets

Equipment List

Trim Press Cells :

  • 3-6 ton Trim Press
  • 1-20 ton Trim Press
  • 1-35 ton Trim Press
  • 10 – 8 ton Trim Press
  • 2-10 ton Trim Press
CNC Machining

Machining Centers :

  • 3 – CNC Vertical milling center with pallet changer
  • 3 – CNC Vertical milling machine

Machine fixtures and CNC centers capable of producing tolerances of +/- . 00025

Deburring

Tumble Deburring:

  • Commercial type hardware finish.
  • Utilizes a part on part barrel action to polish the casting surface, remove flash, and reduce sharp edges.
Finishing

Vibratory Finishing:

  • Premium visual cosmetics
  • Utilizes plastic and ceramic medias to polish the casting surface and reduce sharp edges.
Additional Process

Annealing
Assembly
Black Zinc Chromate
Bright Nickel Plating
Bright Zinc Chromate
Chromate Conversion
Clear Anodizing
E-Coating

Electroless Nickel *(Barrel Plating)
Electroless Nickel *(Rack Plating)
Liquid Paint
Pad Printing
Powder Coat Paint
Shot Bead Blasting
X-Ray
Yellow Zinc Chromate