DIE CASTINGAluminum · Zinc · Dies · Machining · Finishing
Zamak die casting
Zinc die castings for small, detailed and plated parts
Zamak 3 and Zamak 5 melt at about 385 °C and are cast on hot chamber machines, where the injection system sits in the molten zinc. They fill walls under 1 mm on small parts, reproduce fine detail, hold dimensions closely, and the cast surface takes nickel and chrome plating well. The die runs much cooler than in aluminum casting, so zinc dies typically last several times longer.
Zinc suits small and medium parts: lock bodies and door hardware, furniture and bathroom fittings, decorative trim, connector housings, small gears and levers. Check two limits at the design stage. Zinc is about 2.5 times as heavy as aluminum, and Zamak creeps under sustained load, more so above roughly 50 °C (typical).
Typical zinc die cast parts
- Lock bodies, handles and door hardware
- Furniture and bathroom fittings
- Decorative knobs, badges and trim
- Connector and electronics housings
- Small gears, levers and mechanism parts
- Parts for nickel and chrome plating
Zinc die casting at a glance (typical)
| Common alloys | Zamak 3, Zamak 5, Zamak 2 |
|---|---|
| Machine type | Hot chamber |
| Wall thickness | Thinner than aluminum; under 1 mm is common on small parts |
| Draft | Typically about 0.5–1°, less than aluminum |
| Die life | Typically several hundred thousand to over a million shots, far longer than aluminum dies |
| Surface options | Copper, nickel and chrome plating, powder coating, painting, polishing |
Zinc die casting FAQ
Zamak 3 or Zamak 5?
Zamak 3 is the default: stable dimensions, good ductility, easy to plate. Zamak 5 contains about 1% copper for higher strength and hardness, with somewhat lower ductility.
Why choose zinc instead of aluminum?
For small, detailed parts that need thin walls, close dimensions and a plating-quality surface. Zinc is about 2.5 times as heavy as aluminum and creeps under sustained load, so larger, weight-sensitive or loaded parts near heat are usually better in aluminum.
Can zinc die castings be chrome plated?
Yes, it is routine for hardware and decorative parts: polishing, a copper strike, then nickel and chrome. Plating shows every surface flaw, so cosmetic faces, gate positions and parting lines are agreed before the die is made.