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Zinc Pressure Die Casting: An Efficient Manufacturing Process for Complex Parts

Zinc pressure die casting, also known as hot chamber die casting, is a manufacturing process used to produce accurate, high-quality metal parts at high volumes. It involves forcing molten zinc alloy into hardened steel dies under high pressure. The end result is a complex metal part that has excellent dimensional consistency and a smooth surface finish.

Compared to other casting methods, zinc pressure die casting offers several advantages:

Speed and Efficiency
The zinc pressure die casting process is extremely fast. Cycle times range from 10 seconds for small parts to 1 minute for large components. This high production rate makes it ideal for mass manufacturing. The automated nature of the process also results in very efficient production with low labor costs.

Design Flexibility
Zinc alloy castings can be made into nearly any conceivable shape, with excellent detail resolution down to 0.25 mm. Thin walls, complex geometries, and precision features are all possible. This allows designers great freedom in part design.

Material Properties
Zinc alloys have high ductility and impact strength, making them suitable for parts subject to high stress. The rapid solidification also leads to fine microstructures and excellent mechanical properties. Common alloys like Zamak 3 offer strength comparable to mild steel.

Economical for Medium to High Volume Production
Due to fast cycle times, zinc die casting has very low costs per part for production runs of 1000 units or more. It is significantly more economical compared to other processes like sand casting or investment casting for medium to high production volumes.

Limitations of Zinc Pressure Die Casting

While zinc die casting provides many benefits, the process does have some limitations:

High Tooling Costs
The hardened steel dies used in zinc die casting are very expensive, with costs ranging from $5,000 to $100,000. This means that zinc die casting is rarely economical for short production runs of less than 1000 parts.

Design Restrictions
There are some design restrictions to keep in mind. Wall thicknesses usually range from 0.5mm to 3mm. Unsupported walls over 100mm long may require ribs or bosses to avoid sagging. Avoid deep recesses, sharp internal corners, and other features that make it difficult to fill the die cavity.

Limited Alloy Choice
The main alloys used are Zamak alloys 3, 5, and 7. Alloying options are restricted compared to other processes due to the hot chamber nature of zinc die casting. Avoiding melt compatibility issues also limits alloy choices.

Secondary Machining Often Required
The process leaves a small amount of flash around the parting lines. Additional machining like drilling, tapping, and milling may be required to produce the final part. Allowances for trimming and machining need to be considered early in the design stage.

Precifine Die Casting: Producing Quality Zinc Castings

Precifine is a renowned zinc die casting company located in Changzhou, Jiangsu, China. The company specializes in manufacturing high-precision zinc alloy die castings for the communications, electronics, and automotive industries.

Precifine operates a state-of-the-art die casting foundry with advanced equipment made by Italy's Idra and Germany's Frech. Key capabilities at Precifine include:

- Hot chamber zinc die casting machines with clamping forces from 100 to 1600 tons. Capable of producing parts weighing 5 grams to 8 kilograms.

- Fully automated production cells with robots for efficient, high-volume production. Reduces labor costs.

- Vacuum assisted casting technology to reduce porosity and improve mechanical properties.

- Stringent process controls to ensure dimensional accuracy and repeatability from the first to the thousandth part.

- Advanced die design, simulation, and manufacturing techniques including CNC machining, EDM, and wire cutting. Ensures top die quality.

- In-house secondary processing like CNC machining, vibratory finishing, chromating, powder coating, and laser engraving. Provides complete ready-to-use parts.

Precifine provides end-to-end solutions from design and tooling to final precision casting. Their engineering team works closely with customers right from concept to delivery. State-of-the-art analysis software is used to optimize designs for castability and minimize scrap. Customers can expect high-quality, cost-effective zinc die cast parts produced with leading-edge technology and expertise.

Advantages of Zinc Alloys Used By Precifine

Precifine uses Zamak alloys for the majority of its zinc die casting production. Zamak alloys provide an excellent combination of castability, strength, and economy.

Key benefits of Zamak alloys include:

- Excellent fluidity allows for production of thin walls and high detail in complex shapes. Reduces scrap rates.

- Low melting points (~380 to 420°C) make it ideal for hot chamber die casting processes with faster cycles.

- Addition of aluminum and copper provides high strength properties without impacting castability.

- Corrosion resistant and can be plated for decorative finishes or improved corrosion protection.

- Low specific gravity around 6.5 g/cm3 reduces component weight. Important for automotive parts.

- Excellent machinability and polishability. Can produce good surface finishes.

- Low cost alternative to higher priced aluminum or magnesium alloys. Reduces part cost.

Common Zamak alloys used by Precifine are:

- Zamak 3 (ZA3) – The most widely used zinc alloy with well-balanced properties. Yield strength ~240 MPa.

- Zamak 5 (ZA5) – Higher strength (300 MPa yield strength) but lower elongation. Used for high-stress applications.

- Zamak 7 (ZA7) – Includes 1% copper for increased strength and hardness. Used for parts needing good wear resistance.

Precifine leverages its expertise in Zamak alloys to deliver high-quality but cost-effective zinc die cast parts to its global customer base.


Zinc pressure die casting provides an economical means of producing complex, high-precision metal components at production volumes of 1000+ units. It offers numerous advantages including design flexibility, high production rates, and excellent mechanical properties. Precifine Die Casting utilizes advanced zinc die casting capabilities to serve major industries worldwide. By partnering with Precifine for your zinc die casting needs, you can benefit from their cutting-edge facilities, stringent quality control, and experience with Zamak alloys. The result is high-quality castings produced efficiently and cost-effectively. CNC Milling