Capabilities
Zinc Die Casting Services
High-precision zinc die casting (±0.05mm) with electroplating, sandblasting and painting. Prototyping to mass production. Salt spray certified for automotive and electronics
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What is Zinc Die Casting?
Zinc die casting operates through a thermally integrated hot-chamber system, injecting molten ZAMAK alloys (solidus 380°C) into lubricant-coated steel dies under 65-95MPa pressure. The material’s intrinsic properties – including 1.5-2.5% linear shrinkage and 325-425MPa tensile strength – enable 0.1-0.4mm wall thickness precision with ±0.025mm dimensional tolerance. Process economics derive from 300°C lower melt temperatures versus aluminum, yielding 2.8X extended die service life (1M+ cycles) and 40% lower per-unit costs for high-volume automotive fasteners and IoT device housings requiring <50μm surface roughness.
At CastMold, we optimize zinc die casting with 3D-validated DFM guidance, 7-day rapid prototyping . Our integrated process accelerates product development cycles by 30% while maintaining ±0.05mm tolerances, supporting seamless transition from prototypes to 50,000+ unit production runs.
Steps of the Zinc Die Casting Process
The zinc hot-chamber die casting process comprises four critical control phases with quantified parameters:
Die Preparation
Molten Injection
Solidification Control
Finishing & Inspection
ONE-STOP DIE CASTING SOLUTION
We go beyond traditional die casting. Our end-to-end service spans design optimization, rapid prototyping, high-volume production, and precision finishing. From concept to final part, we streamline your workflow with expert collaboration, rigorous quality control, and fast turnaround—all in a single trusted partnership.
- Design Optimization: Leverage simulation-driven DFM (Design for Manufacturing) analysis to enhance part geometry, minimize material waste, and ensure cost-efficient production feasibility.
- Rapid Prototyping: Deliver functional prototypes in 5-7 days using CNC machining or 3D-printed patterns for design validation and tolerance verification.
- High-Volume Production: Scale seamlessly with automated high-pressure die casting (HPDC) systems and real-time process monitoring for consistent output at 10,000+ unit batches.
- Precision Finishing: Apply tailored surface treatments (anodizing, shot blasting) and CNC machining to achieve Ra 0.8μm surface roughness or tighter per ISO 1302 standards.
One Stop Die Casting Service
Die Casting Prototyping
We offer complete prototyping services from 3D printing to functional die-cast samples, significantly reducing product validation cycles.
- Multi-material capabilities (engineering plastics and metals) combined with rapid CNC machining for greater design flexibility
- Hybrid prototyping workflow shortens lead times by 25% while ensuring geometric compliance with mass production requirements
Die Casting Tooling
Our high-precision mold design, integrated with CAE-optimized gating systems, effectively reduces porosity and ensures stable filling performance.
- Modular mold design enables multi-cavity production and insert molding for complex part requirements
- Proprietary surface treatments and tool maintenance programs extend mold lifespan by 40%
Zinc Die Casting
Vacuum-assisted high-pressure die casting technology enables ultra-thin aluminum castings (minimum 0.6mm wall thickness) for lightweight, high-strength structures.
- Process controls for specific alloys (A380/ADC12) ensure mechanical properties meet ASTM/ISO standards
- Combined T6 heat treatment and X-ray inspection to meet automotive industry demands for structural integrity
Secondary CNC Machining
We deliver ±0.01mm ultra-precision CNC finishing for critical sealing surfaces and mating interfaces.
- 5-axis simultaneous machining efficiently handles deep-cavity parts and complex undercut geometries
- In-process CMM inspection guarantees compliance with GD&T standards for every production batch
Die Casting Surface Finishing
Achieve Ra0.2μm mirror finishes via multi-stage polishing or opt for fingerprint-resistant textured coatings through anodization.
- Custom PVD coatings (e.g., TiN/CrN) provide wear resistance up to 1,200HV in harsh environments
- RoHS-compliant electrophoretic coating delivers over 500-hour salt spray corrosion resistance
CastMold Die Casting Capabilities
Excellent Die Casting Quality
Through strict quality control measures and precise rejection criteria, our production system guarantees dimensional accuracy and aesthetic integrity in every casting. By implementing quantifiable surface finish standards, we ensure quality alignment between design specifications and manufactured components.
- Dimensional metrology (CMM with ±2μm repeatability)
- Material verification (XRF spectrometry compliant with ASTM E1621)
- Structural integrity testing (X-ray/CT scanning for porosity ≤0.2%)
- Environmental compliance (RoHS/REACH certification)
- Corrosion resistance validation (1000hrs salt spray testing per ASTM B117)
Die Cast Parts Engineering Support
CastMold’s seasoned engineering team partners with clients from concept development to mass production, delivering design-driven manufacturing excellence.
DESIGN-TO-PRODUCTION ENGINEERING SOLUTIONS
Our engineers leverage advanced CAE simulations and 20+ years of die-casting expertise to:
- Optimize product/tooling designs for manufacturability using CAD/CAM integration
- Conduct mold flow analysis to prevent defects (porosity, warping) during filling/solidification
- Streamline prototyping-to-production transitions through virtual verification systems
- Implement value engineering strategies for cost-efficient material usage and process optimization
- Proficiency in Pro/Engineer and parametric modeling ensures seamless translation of digital designs into high-performance tooling and cast components.
Die Casting
Products Gallery
From compact high-tolerance components (±0.05mm) to heavy-duty structural assemblies, we engineer defect-free die-cast parts in aluminum/zine alloys for automotive, robotics, and consumer electronics.
Types of Die Casting Processes
CastMold delivers tailored die casting solutions through Hot Chamber and Cold Chamber Die Casting technologies, optimized for diverse materials (aluminum, zinc) and production scales. Our expertise ensures seamless adaptation to your project’s structural complexity, volume demands, and cost targets.
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Hot Chamber Die Casting
Cold Chamber Die Casting
Applications of
Zinc Die Casting
- Automotive：Automotive Industry
- Consumer Electronics: Heat sinks, housings for laptops, and 5G communication devices
- Home appliances: Lightweight brackets, sensor housings, and UAV components
- Mechanical sector: Pump housings, hydraulic valves, and robotic arm parts
- Renewable Energy: Solar panel frames, wind turbine gearbox components
Advantages of
Zinc Die Casting
- Lightweight Strength: High strength-to-weight ratio (e.g., ADC12 alloy with 230+ MPa tensile strength).
- Corrosion Resistance: Natural oxide layer ensures durability in harsh environments.
- High Thermal: Conductivity Ideal for heat dissipation in electronics and automotive systems.
- Precision & Complexity: Tolerances as tight as ±0.1mm for intricate geometries.
- Sustainability: 100% recyclable material with reduced energy consumption vs. steel.
Disadvantages of
Zinc Die Casting
- High initial tooling costs: Complex mold designs and high-pressure die-casting machines require significant upfront investment, limiting small-batch production viability.
- Design limitations for thin walls: Fluidity challenges in molten aluminum restrict ultra-thin wall designs (<1mm), impacting lightweight optimization in some applications.
- Internal porosity risks: Rapid cooling during casting can create micro-voids, potentially compromising structural integrity for high-stress components.
- Limited high-temperature performance: Aluminum's lower melting point (660°C) and thermal conductivity make it unsuitable for extreme heat environments vs. steel/titanium alloys.
- Surface finishing requirements As-cast surfaces often require secondary machining/anodizing to achieve precise tolerances or corrosion resistance, adding production steps.
