Zinc die-casting is an efficient and cost-effective solution for technical components that demand high precision, strength and attractive surface finishes. At Linimatic we produce zinc parts both small and large — from just a few grams up to 4 kg.
Compared to aluminum die-casting, zinc offers shorter cycle times, lower energy consumption, and significantly longer tool life. Altogether, this often means lower production costs per part — especially for larger series and parts with a favorable material weight.
Zinc's excellent flow properties also make it possible to cast complex geometries, thin wall thicknesses, fine detail and tight tolerances. This reduces the need for CNC machining and other post-processing, further contributing to a competitive price on the finished part.
Short cycle times and an efficient casting process can result in a lower price per part — especially in larger production series.
Zinc's excellent flow properties make it possible to die-cast advanced shapes, fine details, and integrated features into a single component.
Zinc die-casting provides high dimensional accuracy and good dimensional stability, reducing the need for subsequent machining.
Zinc can fill very narrow sections of the mould, making it well suited for components with thin walls and fine details.
Zinc alloys combine high mechanical strength with good stiffness and are well suited for load-bearing technical components.
Zinc's low melting temperature puts less stress on the mould than aluminum, often resulting in significantly longer tool life. As the tooling cost is amortized over more parts produced, it results in a lower tooling cost per part.
Zinc produces a smooth, uniform as-cast surface suited for both visible components and subsequent surface treatment.
Threads, ribs, bosses, logos and other features can often be integrated directly into the casting. This can reduce the number of components and assembly operations.
Zinc is electrically conductive and can be used for housings and components that need to shield electronics from electromagnetic interference.
Zinc can be recycled again and again without losing its fundamental properties. Production scrap can be remelted and returned to the material cycle.
Side-by-side comparison of zinc die-casting against aluminum, magnesium, and plastic injection moulding. The data explains why zinc wins when precision, surface quality, and tool economics are the deciding factors.
| Property | Zinc | Aluminum | Magnesium | Plastic |
|---|---|---|---|---|
| Achievable Tolerance | ±0.05 mm | ±0.1 mm | ±0.08 mm | ±0.1 mm |
| Die Life (shots) | 1M+ | 100–200K | 200–300K | 500K–1M |
| Cycle Time | 5–45s | 30–120s | 20–60s | 15–60s |
| Min. Wall Thickness | 0.6 mm | 1.5 mm | 1.0 mm | 0.5 mm |
| Surface Finish (Ra) | 0.8 μm | 1.6 μm | 1.2 μm | 0.2 μm |
| Tensile Strength | 280–400 MPa | 150–300 MPa | 200–250 MPa | 30–80 MPa |
| Recyclability | 100% | 100% | 100% | Limited |
The comparison applies to functionally equivalent components manufactured in series production. The values are indicative, as the result depends on the component's design and size, the alloy selected, the tooling, and the production setup.
Zamak alloys are zinc-aluminium alloys optimised for die-casting. The right alloy depends on your part’s mechanical requirements, surface finish needs, and casting complexity. We cast all four standard grades and advise on selection during DFM review.
| Alloy | Tensile Strength | Elongation | Hardness (Brinell) | Primary Use |
|---|---|---|---|---|
| Zamak 2 | 397 MPa | 7% | 100 | High-strength structural components, die-cast bearings, heavy-duty hardware |
| Zamak 3 | 283 MPa | 10% | 82 | General purpose — the most widely cast zinc alloy. Excellent plating characteristics. |
| Zamak 5 | 331 MPa | 7% | 91 | Higher strength than Zamak 3 with good ductility. Automotive and industrial components. |
| Zamak 8 | 374 MPa | 8% | 103 | Highest strength and creep resistance of any zinc alloy. Suited to heavily loaded and heat-exposed parts. |
Zinc die-casting is a manufacturing process where molten zinc alloy is injected under high pressure into a steel die. The hot-chamber process keeps the alloy molten inside the machine, enabling cycle times as fast as 5–6 seconds. The result is a net-shape metal component with tight tolerances, excellent surface finish, and high repeatability — suitable for production volumes from hundreds to millions of parts.
Zamak is a family of zinc-aluminium alloys specifically developed for die-casting. The name comes from the German abbreviations of its constituents: Zink, Aluminium, Magnesium, and Kupfer (copper). The four standard grades — Zamak 2, 3, 5, and 8 — offer different balances of strength, ductility, and castability. Zamak 3 is the most widely used, while Zamak 2 provides the highest strength.
Zinc is the base element. Zamak is a specific family of zinc alloys engineered for die-casting, containing precisely controlled amounts of aluminium (3.5–4.3%), magnesium, and in some grades, copper. Pure zinc is too soft for most engineering applications — the alloying elements in Zamak provide the strength, hardness, and castability that make precision die-casting possible.
Yes, in terms of tensile strength. Zamak alloys range from 283 to 397 MPa, while most die-cast aluminium alloys deliver 150–300 MPa. Zinc also achieves tighter as-cast tolerances (±0.05 mm vs. ±0.1 mm) and produces chrome-ready surfaces without secondary polishing. However, aluminium is lighter (2.7 g/cm³ vs. 6.6 g/cm³), so the choice depends on whether strength-to-weight ratio or absolute precision is the priority.
Magnesium is the lightest of the three metals — lighter even than aluminium. However, zinc dies typically last over 1 million shots versus magnesium’s 200,000–300,000, tolerances are tighter (±0.05 mm vs. ±0.08 mm), and the strongest Zamak alloys exceed magnesium’s tensile strength (up to 397 MPa vs. 200–250 MPa). Magnesium can be the right choice when weight is the overriding factor — for most engineering parts, zinc offers better tooling economics, precision, and strength.
Yes, and this is one of zinc’s strongest advantages. Zinc die-castings have a smooth, consistent surface straight from the die, giving an excellent starting point for chrome plating. The surface must still be polished before plating to achieve a flawless, mirror-bright result. This makes zinc the preferred material for visible, decorative components in furniture, lighting, and consumer products where a flawless chrome finish is mandatory.
Untreated zinc has good natural corrosion resistance and can often be used without surface treatment for indoor or hidden components. For outdoor use, humid environments, or where appearance and wear resistance matter, we offer a wide range of surface treatments — we help select the right option based on the part’s application.
Zinc die-cast components are delivered to a wide range of segments: industrial equipment, automotive, telecommunications, camera housings, and furniture and design products. What these customers share is a need for high precision, complex geometry, and reliable quality — across both small and large production runs.
Zinc is 100% recyclable with no degradation of material properties. Its lower melting point (385°C vs. 660°C for aluminium) means less energy per casting cycle. At Linimatic, virtually all casting scrap — runners, overflows, and reject parts — is remelted and reused directly in production. We also offer lead-free zinc alloys through our Zinkers product line.
Tooling cost depends on part complexity and number of cavities, typically ranging from €10,000 to €80,000. However, zinc dies last over 1 million shots — 5–10× longer than aluminium dies — dramatically reducing per-part tooling cost at volume. Piece prices depend on part weight, alloy, cycle time, and secondary operations. Send us your drawing for a specific quote — we respond within 48 hours.
We’ll tell you honestly whether zinc is right for your part — or recommend an alternative if it isn’t. No sales pressure, just engineering expertise.
