Zamak Die Casting Services
Precision hot-chamber die casting of Zamak 3, Zamak 5 and ZA-27 zinc alloys from our China workshop. Thin walls down to 0.4mm, excellent dimensional accuracy, plating-ready surfaces and free DFM analysis.
Free Consultation24h
Rapid Quote
0.4mm
Min Wall
China
Factory
500 pcs
MOQ
Materials
| Grade | Properties | Typical Applications |
|---|---|---|
| Zamak 3 | Tensile Strength: 283 MPa, Density: 6.60 g/cm³, excellent dimensional stability, superior castability and surface finish, high ductility | Hardware, locks, connectors, automotive interior trim, handles, decorative components |
| Zamak 5 | Tensile Strength: 328 MPa, Density: 6.70 g/cm³, higher strength and hardness than Zamak 3, slightly less ductility | Structural brackets, gear housings, mechanical parts, automotive and appliance components |
| ZA-27 (Zinc-Aluminum 27%) | Tensile Strength: 400-440 MPa, Density: 5.00 g/cm³, high strength, good bearing and wear properties, castable by cold or hot chamber | Bearings, bushings, sprockets, structural parts needing higher strength than Zamak |
| Zamak 2 / Zamak 7 | Zamak 2: highest strength Zamak, less ductile; Zamak 7: high fluidity for thin intricate sections | Zamak 2: heavy-duty fittings; Zamak 7: miniature and thin-wall decorative parts |
Process Parameters
| Parameter | Standard Range |
|---|---|
| Casting Process | Hot-chamber die casting (zinc alloys melt below 450°C, ideal for high-volume thin-wall parts) |
| Dimensional Tolerance (As-cast) | ±0.05mm standard, ±0.02mm on machined faces |
| Minimum Wall Thickness | 0.4mm (typical), down to 0.3mm for very fluid thin sections |
| Surface Roughness (As-cast) | Ra 1.6μm - 3.2μm, smoother than aluminum or magnesium die casting |
| Draft Angle | 0.5° - 1.5° per side, less than aluminum because of zinc stiffness |
| Max Part Size | Up to 600mm for typical zinc parts; larger possible |
| Die Steel | H13, 8407, or pre-hardened steels; zinc is less abrasive so dies last longer |
| Die Life | 500k - 1M+ shots depending on complexity and steel grade |
Surface Finishes
As-Cast
Smooth natural die cast surface (Ra 1.6-3.2μm), often good enough for decorative use after tumbling. Zinc casts smoother than aluminum.
Vibratory Tumbling
Deburring and edge radiusing for safe handling and consistent appearance; also removes parting-line flash.
Bead Blasting
Uniform matte texture that hides minor flow lines and improves coating adhesion.
Plating (Chrome / Nickel / Zinc)
Zinc die castings plate exceptionally well – bright chrome, satin nickel or zinc plating for corrosion resistance and premium appearance. A key advantage over aluminum.
Powder Coating
Durable polyester/epoxy coating, 60-120μm, wide RAL/Pantone range, excellent corrosion protection for indoor and outdoor parts.
Painting (2K / UV)
Automotive-grade paint systems with custom colors, soft-touch and matte/gloss options for consumer products.
Design for Manufacturing (DFM)
- Free DFM review of casting geometry within 24 hours
- Maintain minimum wall thickness of 0.4mm (zinc allows thinner walls than aluminum); keep wall sections uniform to avoid shrink and warpage
- Design 0.5° - 1.5° draft per side so parts eject cleanly without drag marks
- Use generous fillets (≥0.5mm) at wall junctions to reduce stress and porosity
- Place gates and runners to feed thick sections last and minimize cold shuts
- Locate ejector pins on non-critical, supported surfaces to avoid read-through marks
- Design bosses and ribs rather than thick solid sections to control weight and shrinkage
- Specify machining stock only on faces needing tight tolerance, then CNC to ±0.02mm after casting
Tooling & Capacity
| Type | Lead Time | Suitable For |
|---|---|---|
| Prototype Die (Soft / Aluminum) | 2-3 weeks | 500-2,000 pieces, design validation and pre-production |
| Production Die (H13 / Pre-hardened) | 4-6 weeks | 100k-1M+ shots, high-volume decorative and functional parts |
| Multi-Cavity Die | 5-7 weeks | High-volume production, 2-16 cavities for lower per-piece cost |
Quality Assurance
- Incoming metal verification – zinc alloy composition checked on incoming ingot lots
- First Article Inspection (FAI) with CMM measurement; full dimensional report shipped with first article
- In-process checks at casting, trimming and CNC stations to catch variation early
- Critical features checked with calipers, gauges and CMM dimensional inspection
- Surface inspection for cold shuts, porosity, flow lines and flash per specification
- Plating and coating thickness verified where specified
- Lot traceability with inspection records retained for each production batch
- Final inspection and packing with anti-corrosion protection for transit
Applications
- Hardware and locks: bodies, housings, handles, brackets, fasteners
- Automotive interior: trim, brackets, connectors, bezels, mirror housings
- Electronics: connector shells, enclosures, EMI shields, switch bodies
- Power tools: gear housings, clutches, trigger guards, structural brackets
- Consumer products: decorative frames, zippers, badges, premium cosmetic parts
- Plumbing and fittings: valve bodies, couplings, faucet components
- Toys and hobby: miniature structural and decorative parts
- Industrial: bushings, bearings (ZA-27), sprockets, mechanical linkages
Why Choose FHY Precision
Thin-wall capability: walls from 0.4mm with high dimensional accuracy – lighter parts and less material than aluminum
Superior surface finish: zinc casts smoother than aluminum, taking plating and paint beautifully
Excellent platability: bright chrome and nickel plating adhere well, a major advantage for decorative parts
Long die life: zinc is less abrasive than aluminum, so tooling lasts longer and per-piece cost drops
High dimensional stability: Zamak holds tight tolerances with low post-cast distortion
Fast cycle times: hot-chamber process cycles faster than cold-chamber aluminum, lowering volume cost
Free DFM analysis: upload STEP/IGES for a report within 24 hours on walls, draft, gates and cost
One-stop service: casting, CNC machining, plating, powder coat and inspection from our China workshop
FAQ
1. What is Zamak and how is it different from aluminum die casting?
Zamak is a family of zinc-aluminum (Zn-Al-Cu-Mg) die casting alloys (most commonly Zamak 3 and 5). Compared with aluminum, zinc is cast by the hot-chamber process at lower temperature, allows thinner walls (from 0.4mm), casts a smoother surface, plates far better, and gives longer die life. Aluminum wins on weight and heat resistance. We help you choose in the free DFM review based on wall thickness, finish and volume.
2. Which Zamak grade should I use?
Zamak 3 is the default: best dimensional stability and castability for most decorative and general parts. Zamak 5 adds strength and hardness for structural brackets and mechanical housings. ZA-27 (27% aluminum) delivers the highest strength and good bearing properties for bushings and sprockets. Zamak 7 flows best for very thin, intricate sections. Tell us the application and we will recommend the grade.
3. What wall thickness can you cast in Zamak?
Typical minimum wall is 0.4mm, and down to about 0.3mm for small fluid sections. Zinc supports thinner walls than aluminum or magnesium, which is why it is favored for lightweight, material-saving decorative and electronic parts. Keep walls uniform to avoid shrinkage and warpage.
4. What tolerances can you achieve?
As-cast tolerance is ±0.05mm standard, with ±0.02mm achievable on CNC-machined faces after casting. Geometric features such as flatness and position are held to customer print. We review tolerance strategy in the DFM report.
5. What surface finishes are available for Zamak parts?
Zamak is usually delivered as-cast (Ra 1.6-3.2μm) or tumbled. It plates exceptionally well – bright chrome, satin nickel or zinc plating – and also takes powder coating and painting. Plating is the standout option for premium decorative finishes.
6. What is your minimum order quantity?
MOQ is 500 pieces for die casting because tooling is required. Prototype dies (2-3 weeks) start lower for validation. We will advise the most economical entry volume in the quote.
7. How long does Zamak die casting take?
Prototype die: 2-3 weeks with T1 samples a few days after. Production die: 4-6 weeks. After tooling, recurring production runs ship in 1-3 weeks depending on quantity. We confirm dated lead times with every quotation.
8. Can I get a sample before mass production?
Yes. We recommend approving a T1 trial shot or prototype sample before full production. Mass production begins only after you sign off on the sample and dimensions.
9. Do you provide CNC machining after casting?
Yes. Critical faces, bores and threads are CNC-machined after casting to ±0.02mm. We design machining stock into the tool so tight-tolerance features are reliable and repeatable.
10. Can you sign an NDA and protect my design?
Yes. NDA signage is standard before we review files. We restrict drawing access to the project team and never show your parts without written permission.
11. Do you ship Zamak parts internationally?
Yes, worldwide by express (3-7 business days) for samples or by air/sea freight (2-6 weeks) for volume. Export paperwork includes commercial invoice, packing list and origin documentation; parts are packed with anti-corrosion protection.
12. How is Zamak die casting priced?
Price = Tooling amortization + Material + Machine cycle + Finishing + Inspection. Because zinc cycles fast and dies last long, per-piece cost drops sharply at volume. We provide an itemized quote within 24 hours, and the DFM report flags design changes that cut cycle time and material.
13. What are the most common Zamak casting defects, and how do you prevent them?
The usual suspects are gas porosity, cold shuts, flow marks, flash at the parting line, ejector marks and sink marks over thick sections. Prevention is a design and tooling discipline, not an inspection activity: balanced wall thickness (avoid thick islands), generous venting, controlled fill speed, correct gate and overflow design, and uniform die temperature. We review porosity risk on your drawing before tooling – which surfaces are cosmetic, which are sealing, which dimensions are critical – and plan the tooling around those answers.
14. What is the maximum service temperature for Zamak parts?
Historically the guidance for Zamak 3 and 5 is an upper service temperature of about 100°C under sustained load, and up to 150°C for unstressed applications; Zamak 2 reaches roughly 130°C stressed. Zinc alloys also creep under sustained load, so a bracket carrying force next to a 110°C motor is outside the design envelope. If your part runs hot under load, tell us the temperature and load case during quoting – aluminum or a engineered plastic may be the honest recommendation.
15. Does Zamak corrode? What is white rust?
Zinc corrodes protectively rather than catastrophically – where galvanized steel performs, zinc castings usually perform too, except in severe marine environments. Where condensation sits on a bare part, it forms white rust: a cosmetic zinc-oxide film that is acceptable on a bare part but a reject on a finished one. The serious failure mode is intergranular corrosion, driven by lead, cadmium and tin impurities in the melt – it swells and cracks parts months or years into service. High-purity zinc and disciplined recirculation prevent it, which is why melt control is a certification-grade topic for us.
16. How long does a Zamak die last compared with aluminum die casting?
Zinc runs cool (around 420°C melt) against a machine and die that see far less thermal shock than aluminum casting, so Zamak dies routinely exceed one million shots – often several times the life of an aluminum die in the same size class. Hot-chamber gooseneck and nozzle are consumables and their wear shows up in the part before maintenance notices, so we track shot counts and service the tool on schedule. For your program, a Zamak tool amortizes over a very large part count.