High-pressure die casting is at the core of everything we do. At our foundry in Helsinge, 9 robotized casting cells run around the clock, producing zinc parts from 1 gram to 4 kilos — from small precision components to large, complex parts. The process is monitored continuously, so quality stays the same from the first shot to the last. With as-cast tolerances down to ±0.05 mm, many parts can be used without any secondary machining. That makes us Denmark’s largest dedicated zinc die-casting foundry — and the natural choice when the part is difficult and the requirements are high.
The Zamak alloy is kept molten in the machine’s integrated furnace at a tightly controlled temperature. The zinc is forced directly from the furnace into the die tool — fully controlled and automated, in one closed system, with no manual handling. The result is faster casting cycles and consistent quality, shot after shot.
Molten zinc is injected into the hardened die tool at pressures up to 200 MPa. Fill times under 50 ms ensure optimal cavity fill even in thin-walled and complex geometries, with minimal porosity.
Parts are extracted by robotic arms within seconds of solidification. Runners and overflows are separated from the part and either returned immediately to the furnace or remelted for reuse — helping keep the CO2 footprint low.
Process verification is carried out according to the requirements agreed with the customer at the quotation stage. CMM spot-check inspections and SPC data (statistical process control) are used to ensure the process remains stable.
Our 9 robotized casting cells cover the full tonnage range from 20T for small precision components to 315T for large structural parts — all with robotic handling. That singular focus gives us the deep process knowledge it takes to cast complex parts.
Our experience with casting process simulation is rare in the industry. We simulate fill, solidification, and porosity before the tool is even built, so we get an optimized die from the very first shot. That lets us cast highly complex products where others have to give up. The same experience makes us a natural choice for high-end products and other demanding projects — including complex solutions for casting other metal components directly into the part during the die-casting process, where tolerances and material interaction have to be precisely matched.
Many of our customers’ parts move on to surface treatment and a thorough visual final inspection before they’re ready for use. We have years of experience with this — from choosing the right post-treatment to the final check of appearance and finish before the part leaves the building.
Hot-chamber die casting of zinc is a fast and precise process in which molten zinc at 420°C is injected into a die tool under high pressure. The method is especially suited to series production of complex parts with tight tolerances, thin wall sections, and a fine surface finish.
About 95% of the parts we cast use Zamak 5, our standard alloy — a strong, well-rounded balance of strength, ductility, and castability (331 MPa tensile strength). The remaining 5% we cast in Zamak 8, which we use when Zamak 5’s strength isn’t sufficient — it’s the strongest and most creep-resistant zinc alloy we cast (374 MPa). Beyond that, we can also cast in Zamak 2, which offers the highest hardness and suits bearing surfaces, or Zamak 3, which has the best plating characteristics. We advise on the right choice during the DFM review of your drawing.
We cast parts from 1 g to 4 kg across our 9 casting cells. The optimal machine is selected based on part weight, projected area, and the required clamping force. The number of cavities is determined by the requirements for quality, complexity, and efficiency.
Zinc die-casting tools routinely exceed 1 million shots — 5 to 10 times longer than aluminium die-casting tools. This is because zinc’s lower casting temperature (385°C vs. 660°C for aluminium) creates significantly less thermal stress on the die steel. All tools are maintained under our preventive maintenance programme.
As-cast tolerances to ±0.05 mm are standard on our machines. For features requiring tighter control, secondary CNC machining can achieve even higher precision. We publish tolerance recommendations by feature type (linear, bore, flatness) during DFM review.
Send us your part drawing and volume requirements. We’ll recommend the right alloy, estimate tooling cost, and provide a piece price — within 48 hours.
