Precision Zinc Die Casting Services
High-quality zinc die casting solutions for complex geometries and precision tolerances. From prototype tooling to mass production with competitive China manufacturing costs and strict quality control.
Free Consultation20-30 Days
Tooling Lead Time
±0.05mm
Tolerance Accuracy
500K+ Shots
Tool Life
0.5g - 5kg
Part Weight
Materials
| Grade | Properties | Typical Applications |
|---|---|---|
| Zamak 3 (Zinc Alloy No. 3) | Tensile Strength: 280 MPa, Yield Strength: 220 MPa, Density: 6.6 g/cm³, excellent castability and surface quality | General parts, hardware components, decorative items, consumer electronics housings, automotive parts |
| Zamak 5 (Zinc Alloy No. 5) | Tensile Strength: 340 MPa, Yield Strength: 290 MPa, Density: 6.6 g/cm³, higher strength and hardness than Zamak 3 | Structural components, automotive parts requiring higher strength, industrial equipment, load-bearing applications |
| Zamak 2 (Zinc Alloy No. 2) | Tensile Strength: 360 MPa, Yield Strength: 310 MPa, Density: 6.6 g/cm³, highest strength in Zamak series | High-strength parts, mechanical components, applications requiring excellent mechanical properties |
| Zamak 7 (Zinc Alloy No. 7) | Tensile Strength: 285 MPa, better fluidity and surface quality, lower melting point, suitable for thin-wall casting | Thin-wall parts, complex geometries, parts requiring excellent surface detail and finish |
| ZA-8 (Zinc-Aluminum Alloy) | Tensile Strength: 300 MPa, better creep resistance, superior high-temperature performance | Automotive components, structural parts requiring dimensional stability at elevated temperatures |
Process Parameters
| Parameter | Standard Range |
|---|---|
| Dimensional Tolerance (Precision) | ±0.02mm to ±0.05mm (depending on part geometry) |
| Dimensional Tolerance (Standard) | ±0.05mm to ±0.15mm (general applications) |
| Wall Thickness | 0.8mm - 4.0mm (optimal: 1.5mm - 2.5mm) |
| Draft Angle | 0.5° - 2.0° (recommended: minimum 1.0° for zinc alloys) |
| Part Weight Range | 0.5g - 5,000g |
| Surface Roughness (As-cast) | Ra 1.6μm - 6.3μm (can be improved by polishing) |
| Tool Life | 500,000 - 2,000,000 shots (depending on part complexity) |
| Part Complexity | Complex geometries, undercuts, and thin-wall structures achievable |
Surface Finishes
Mechanical Polishing
Buff polishing for smooth, bright surfaces. Achieves Ra 0.4μm - 1.6μm. Suitable for decorative parts and pre-plating preparation.
Electroplating (Chrome/Nickel)
Chrome or nickel plating enhances aesthetics and corrosion resistance. Thickness: 5-25 microns. Zinc alloys have excellent plating adhesion.
Powder Coating
Durable powder coating with custom RAL colors. Electrostatic application of thermoset coating. Excellent weather resistance and UV protection for outdoor applications.
E-coating (Electrophoresis)
Uniform coating through electrodeposition. Excellent coverage for complex geometries. Thickness: 15-30 microns.
Chemical Conversion Coating (Chromate Treatment)
Chemical conversion coating enhances corrosion resistance and paint adhesion. Clear or yellow chromate treatment available.
Painting
Automotive-grade wet paint application. Custom color matching available. Matte, gloss, metallic, and texture finishes optional.
Brushed Finish
Directional brushed texture for premium appearance. Achieved through abrasive processing. Popular choice for consumer electronics and decorative hardware.
Sandblasting
Shot peening or sandblasting for uniform matte surface. Removes surface imperfections and prepares for coating. Ra 2.5μm - 6.3μm.
Design for Manufacturing (DFM)
- Design uniform wall thickness (variation within ±30%) to prevent porosity, shrinkage defects, and distortion
- Maintain minimum 1.0° draft angle to ensure smooth ejection and extend tool life
- Avoid sharp corners: design minimum 0.5mm - 1.0mm fillet radii to distribute stress
- Design gate and vent locations to ensure smooth metal flow and air evacuation
- Arrange ejector pin positions on non-critical surfaces to maintain cosmetic quality
- Avoid thick wall sections exceeding 6mm to reduce shrinkage and shorten cycle time
- Design bosses and mounting features with adequate draft angles and proper transitions to prevent hot spots
- Include overflow wells to collect air and impurities, improving part quality
- Design sliders and side cores for undercut features with adequate mechanism operating space
- Avoid extremely thin sections below 0.8mm to ensure good metal flow and filling
Tooling & Capacity
| Type | Lead Time | Suitable For |
|---|---|---|
| Prototype Tooling (H13 Steel) | 15-25 days | Prototype validation (500-5,000 parts), design confirmation, small batch production |
| Production Tooling (Premium H13) | 25-40 days | Mass production (500,000+ parts), large-scale manufacturing, long-term projects, tool life 1 million+ shots |
| Single-cavity Tooling | 25-35 days | Single part production, complex geometries, parts requiring higher quality and dimensional control |
| Multi-cavity Tooling | 35-50 days | High-volume production, multi-part assemblies, unit cost optimization, production efficiency improvement |
Quality Assurance
- Comprehensive quality management system with detailed work instructions and inspection standards for all processes
- Incoming inspection: Chemical composition analysis using spectrometer to verify alloy composition
- X-ray inspection for internal porosity and structural integrity
- CMM (Coordinate Measuring Machine) inspection for critical dimensional features
- Surface roughness measurement using roughness tester
- Leak testing (air or water pressure test) for parts requiring sealing performance
- Mechanical property testing: tensile strength, hardness (Brinell or Rockwell), impact testing
- Dimensional capability study (Cpk ≥ 1.33 for critical dimensions)
- Visual inspection for surface defects and casting quality per ASTM E155 standard
- Final inspection report with dimensional data, material certificates, and test results
Applications
- Automotive components: door handles, gear shifters, carburetor bodies, transmission cases, engine parts
- Consumer electronics: mobile phone housings, laptop frames, tablet frames, wearable device housings
- Hardware components: door locks, hinges, cabinet hardware, bathroom accessories, furniture hardware
- Electrical components: connector housings, switch bodies, relay cases, junction boxes, terminal blocks
- Industrial equipment: pump bodies, valve parts, gearbox housings, hydraulic fittings, pneumatic components
- Medical devices: equipment housings, surgical instrument handles, diagnostic device parts
- Power tools: drill housings, gearbox cases, motor frames, handle assemblies
- Decorative items: fashion accessories, jewelry components, trophy parts, premium hardware
Why Choose FHY Precision
Excellent castability: Zinc alloys enable complex geometries, thin walls, and fine details
Superior surface quality: Excellent as-cast surface quality reduces secondary processing requirements
High dimensional accuracy: Near-net or net shape production reduces machining requirements
Tool cost-effectiveness: Long tool life (500K-2M shots), more economical than aluminum die casting
High production efficiency: Short cycle times (1-2 minutes), suitable for mass production
Material versatility: Multiple Zamak alloy options to meet specific mechanical and aesthetic requirements
China manufacturing advantage: Competitive pricing through efficient production without compromising quality
One-stop surface finishing: In-house polishing, plating, and coating capabilities for complete solutions
FAQ
1. What is the minimum order quantity (MOQ) for zinc die casting?
Our zinc die casting MOQ starts from 500 pieces for prototype tooling and design verification or market testing. For production tooling, MOQ typically starts from 2,000 pieces to ensure cost-effectiveness. We offer flexible production volumes from prototype quantities to million-unit mass production orders. We believe low entry barriers help you test the market risk-free before scaling up.
2. What is the typical lead time for zinc die casting tooling and production?
Zinc die casting prototype tooling (H13 steel): 15-25 days. Production tooling (premium H13): 25-40 days. Single-cavity tooling: 25-35 days. Multi-cavity tooling: 35-50 days. First production typically delivers within 4-6 weeks after tooling completion. All lead times include our free DFM review (completed within 24 hours of receiving CAD files).
3. Can you sign a Non-Disclosure Agreement (NDA) before sharing design files?
Yes. We offer NDA signing before quotation, not just before production. Your CAD files, product specifications, and business information are treated as confidential assets. We have served clients in aerospace, medical devices, and consumer electronics sectors—protecting intellectual property is our standard practice, not an exception.
4. What is DFM analysis? Do you provide free DFM?
DFM (Design for Manufacturing) is an engineering review service we provide free of charge, completed within 24 hours after receiving your CAD files. Our engineers check wall thickness, draft angles, gate locations, undercuts, and castability issues before quotation, so you understand the expected results before production begins. Result: fewer modifications, lower tooling costs, and faster time to market.
5. How is pricing calculated? What factors affect my tooling and part costs?
Part price = Material cost + Processing/machining cost + Surface finishing + Volume discount. Tooling price = Tooling complexity × Cavity count × Steel grade (P20 / H13 / S136). We provide detailed quotations within 24 hours. Before sharing formal drawings, you can get a rough estimate based on product description—just send basic specifications and target quantities.
6. What CAD/CAM file formats do you accept?
We accept: STEP (.stp/.step), IGES (.igs), STL, DXF, DWG, Parasolid (.x_t), and PDF drawings. For zinc die casting, STEP files containing 3D models are recommended. If you only have 2D drawings or samples, we can perform reverse engineering to generate 3D models for a small fee.
7. Can I get prototypes/samples before mass production?
Yes, and we make it affordable. Our prototype tooling service can deliver 500-5,000 prototype parts within 2-3 weeks at a fraction of production tooling cost. All prototypes are available with dimensional verification reports upon request.
8. What tolerance precision can you achieve?
Our standard tolerance is ±0.05mm. For precision parts, we can consistently achieve ±0.02mm. For the first 100mm of zinc die casting, tolerance is typically ±0.05mm—for tighter requirements, we achieve it through CNC post-machining. All critical dimensions are measured using calibrated instruments with optional CMM verification.
9. Do you provide international shipping? How is export packaging handled?
We ship globally via DHL, FedEx, and ocean freight. Export packaging follows international standards: rust preventive oil + vacuum bag + wooden crate (IPPC certified for ocean freight). Each shipment includes packing list, Certificate of Origin (COO), and commercial invoice. Typical ocean freight time to USA/Europe is 3-5 weeks from port of shipment.
10. What surface finishing options are available for zinc die casting parts?
We offer mechanical polishing, chrome/nickel plating (zinc alloys have excellent plating adhesion), powder coating, e-coating, chemical conversion coating, painting, brushed finish, and sandblasting. Zinc alloys are particularly suitable for plating due to their excellent surface quality and plating adhesion characteristics. We source surface finishing from certified sub-suppliers to ensure consistent quality.
11. Can you provide one-stop manufacturing services (die casting + CNC + surface finishing + assembly)?
Yes. Beyond our core processes, we offer zinc die casting, aluminum die casting, CNC machining, tool making, surface finishing, and light assembly—all under one roof with a single point of contact. This reduces your supplier management burden and ensures stricter quality control across the entire value chain.
12. Which zinc alloy material should I choose for my product?
The right material depends on your product requirements: Zamak 3: General purpose, tensile strength 280 MPa, suitable for general applications, consumer electronics housings, decorative items. Zamak 5: Higher strength and hardness (tensile strength 340 MPa), suitable for structural parts, automotive components. Zamak 2: Highest strength in Zamak series (360 MPa), suitable for high-strength parts. Zamak 7: Better fluidity and surface quality, suitable for thin-wall casting. ZA-8: Better creep resistance, suitable for elevated temperature applications. Share your requirements (environment, loading, temperature, aesthetics), and our engineers will recommend the optimal material—included in our free DFM service.
13. What is the difference between steel and aluminum molds? Which should I choose?
Aluminum molds: Lower tooling cost (30-50% of steel molds), 2-3 week lead time, approximately 25,000 shot life, suitable for prototypes, pre-production, market validation. Steel molds (H13): Higher tooling cost, 4-6 week lead time, 500,000+ shot life, suitable for mass production (>10,000 parts). Recommendation: Choose aluminum molds for the first 25,000 shots to validate design, then upgrade to steel molds for mass production—FHY offers both options in-house.
14. What common defects should be watched for in zinc die casting?
Our DFM review addresses all these issues before production: Porosity → Incomplete filling or gas entrapment. FHY solution: Optimize gate location and venting. Shrinkage → Uneven cooling in thick wall sections. FHY solution: Uniform wall thickness design (variation within ±30%). Flash (burrs) → Insufficient clamping force. FHY solution: Use die casting machine with adequate tonnage. Distortion → Uneven cooling. FHY solution: Optimize cooling system design. Cold shut → Low pouring temperature or slow speed. FHY solution: Adjust pouring parameters.
15. What is the approximate cost of zinc die casting tooling?
Reference prices (USD, EXW): Simple single-cavity tooling (H13 steel): $3,000 - $8,000. Multi-cavity tooling (2-8 cavities, H13): $8,000 - $25,000. Complex/high-precision tooling: $25,000 - $60,000+. Prototype tooling (aluminum molds): $1,500 - $5,000. Final cost depends on cavity count, steel grade, surface finishing complexity. Send your product drawings, and we will provide a confirmed quote within 24 hours.
16. What advantages does zinc die casting have compared to aluminum die casting?
Zinc die casting excels over aluminum in several aspects: Better surface quality (as-cast Ra 1.6-6.3μm vs aluminum Ra 3.2-12.5μm), suitable for plated decorative parts; Longer tool life (500K-2M shots vs aluminum 100K-300K shots); Lower production costs (lower melting point, 30-40% energy savings); Better dimensional accuracy and stability; Can cast thinner walls (0.8mm vs aluminum 1.5mm); Excellent electromagnetic shielding properties. Suitable for applications requiring high surface quality, plating, small batches, or decorative parts.