Zinc die casting for detailed housings, mechanisms and hardware, with service temperature, loading, mass and decorative finish reviewed together.
Review the component, material specification and delivery requirements together before selecting tooling and production conditions.
Routine weights refer to trimmed single-part castings after gate and runner removal. The 1 g example is specific hot-chamber micro-part production experience. Machine, tooling and shot requirements are reviewed for each new part; the equipment inventory lists machine clamping forces and quantities without assigning them to individual alloys.
Examples of decorative hardware and compact housings. These illustrate component types and review points; the grade, manufacturing route and acceptance criteria are agreed for your project.
A lever-handle example highlights visible surfaces, parting and ejection locations, coating requirements and assembly interfaces.
Agree the finish sample and any fit or functional requirements after coating.
Review finish requirements →
Optical transceiver housings, covers and precision metal components for optical communications equipment.
Review shell and cover fits, mounting features, dimensions after finishing and contact surfaces that must remain uncoated.
Explore optical communications applications →Typical zinc main walls are 0.8–2.0 mm. Local 0.7 mm features are a tooling-trial target, mainly for Zamak zinc with short flow paths. Review filling distance, surface detail, parting lines, coating allowances and assembly interfaces together.
Mark the primary visible faces and agree an appearance sample. Review parting lines, ejector locations, surface defects and handling before tooling release.
Plan tooling & appearance →Specify cleaning and preparation, underlayers and the final finish. Agree coating thickness, adhesion and corrosion-test conditions for the selected grade.
Explore surface finishing →Identify bores, threads, mating dimensions and surfaces that must remain uncoated. Define acceptance before or after finishing and any secondary machining.
Review secondary CNC machining →Material reference values support initial selection. Confirm the specified grade, manufacturing condition and acceptance criteria for the finished component.
Zinc die casting is used for compact housings, mechanisms, hardware and decorative components. Zamak 3 is the reference grade used here. Review Zamak 5 and other zinc alloys against their own specifications, with attention to component mass, service conditions and finishing requirements.
Still comparing materials? Compare casting alloy families →
The following published values refer to Zamak 3. Use these values for initial material comparison. Part acceptance and design properties require the applicable specification, delivery condition and representative test evidence.
| Reference property | Value |
|---|---|
| Density | 6.6 g/cm³ |
| Typical tensile strength | 283 MPa |
| Reference Brinell hardness | 82 |
| Approximate melting range | 381–387°C |
Eastern Alloys Zamak 3 data. Mechanical figures are the supplier's typical die-cast reference values. Casting geometry, internal quality, test method and delivery condition can change the properties of the finished part.
The melting range describes the solidus-to-liquidus interval. Service limits and casting temperatures must be established separately.
Sustained loading requires assessment of creep using the actual stress, temperature, exposure duration and allowable deformation. Review corrosion exposure and appearance requirements for the selected alloy; persistent moisture or aggressive media may require additional surface protection. International Zinc Association: mechanical properties and corrosion behavior
Evaluate thin features together with filling distance, part size, local geometry, draft and ejection. Agree feasible local wall thicknesses during DFM. Confirm slides, cores, cosmetic surfaces and plating requirements before tooling release. Where impact performance is critical, define the alloy, casting quality, service temperature and applicable test requirements.
Zinc processing temperatures can support long die life. Erosion, sticking and ejection-related wear still require monitoring. Agree maintenance, replaceable features and the dimensional or appearance criteria for continued tool use.
Published die-life reference: 500,000–2,000,000 shots, from the Uddeholm tooling guide, page 12. The range counts casting cycles. Confirm actual tool life and core or insert replacement intervals for the project; the reference is not a service-life commitment.
Zamak 3 can be evaluated for plating and painting. Specify cleaning, surface preparation, underlayers and the final coating system. Review machining requirements against the alloy condition, casting quality, tolerances and selected cutting tools.
Agree finish samples, coating thickness, adhesion, corrosion-test conditions and whether dimensions apply before or after treatment. Electrical or thermal contact areas may need defined masking and interface requirements.
At equal solid volume, the reference densities give Zamak 3 approximately 2.44 times the mass of A380. Actual component geometry, secondary operations, yield and tooling amortization determine the cost comparison. Use grade-specific quotations for the same date, quantities and delivery terms.
Compare cost per accepted component, including material utilization and recovery, tooling, production, secondary operations, inspection, rejects, packaging and transport. Energy use also depends on furnace efficiency, holding time and production utilization.
Confirm alloy, size, mass, tolerances, finish and testing requirements during the drawing and DFM review. Record the agreed manufacturing and acceptance requirements before production release.
Provide the operating temperature profile, stress, exposure duration and allowable deformation so creep and long-term dimensional requirements can be assessed.
A suitable grade, surface preparation and coating system can be evaluated. Agree appearance samples, coating thickness, adhesion and corrosion-test requirements.
Define the alloy, service temperature, component geometry and applicable impact test, including sampling and acceptance criteria. Material selection alone does not verify finished-part performance.
Specify the alloy designation, governing standard and required delivery condition on the drawing or material specification. Review composition limits, service requirements, finish and testing before approving a substitution; the two grades should not be treated as interchangeable by default.
Tooling, casting, machining and inspection follow the drawing revision and approvals agreed for the order.
Confirm the grade, geometry, critical features and agreed drawing revision.
Review tool design, trials, sample measurements and approval requirements.
Confirm the machine and process configuration for the zinc part, then cast, trim and deburr to the agreed requirements.
Complete the required functional features, surface treatment and interface protection.
Release parts with the agreed inspection records, identification and packaging.
Die tooling
Casting equipment
Surface-finishing workshop
Workshop views illustrate the supporting manufacturing stages. The machine, zinc casting process, finish system and inspection methods are confirmed for the actual project.
A drawing-based checklist for closing geometry, tooling, machining, finishing, inspection, and approval questions before die manufacture begins.
Read engineering guide →Select and specify finishes for cast and machined parts using material compatibility, service conditions, functional requirements and appearance criteria.
Read engineering guide →A practical guide to tooling, material, geometry, process, machining, finishing, inspection, assembly, and change risks that shape total die casting cost.
Read engineering guide →Send your drawing with the alloy specification and finished-part requirements. Engineering reviews the proposed route and provides clarification questions, next steps or a quotation.
Review My Drawing →Files are stored privately. Contact us before uploading if your project requires an NDA.