By Ozark Die Casting
Die casting is fast, precise, and cost-effective — but not every part is a fit. This guide helps you determine if your machined or fabricated part is a strong candidate for zinc die casting.
We’ve helped hundreds of engineers convert parts and cut costs up to 60%. Here’s how we evaluate conversion potential:
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✅ The Zinc Die Casting Conversion Checklist
1. Volume: Are You Making Enough Parts?
✔ Ideal:
- 500+ units/year
- Stable, long-term designs
- Cost per part matters
✘ Not Ideal: - One-off production
- Frequent design changes
2. Material: Can It Be Replaced with Zinc?
Zinc (ZAMAK 3, 5, ZA-8) often replaces:
- Aluminum, brass, bronze, steel
- Plastics (when strength needed)
✔ Great Fit:
- Needs strength, wear resistance, cosmetic finish
✘ Avoid If: - High heat (>300°F) or weight is critical
3. Geometry: Is the Part Castable?
✔ Great Features:
- Uniform walls
- Ribs, bosses, fillets
- Draft angles for easy ejection
✘ Challenges (often solvable): - Undercuts, sharp corners, reverse draft
4. Tolerances: Are You Over-Specifying?
✔ Typical Casting Tolerances:
- ±0.003–0.005″ (linear)
- ±0.002″/inch (flatness)
- Tighter tolerances with secondary machining
✘ If you need ±0.0005″ everywhere, machining may still be needed
5. Finish: Does Appearance Matter?
Zinc excels at:
- Chrome plating
- Powder coating
- Decorative finishes
- Cosmetic housings
6. Can You Combine Parts?
Die casting allows part consolidation:
- Brackets + fasteners → one casting
- Housing + ribs → integrated part
- Fewer welds, screws, and assembly time
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⚙️ Real-World Example
| Before | After | Result |
|---|---|---|
| 2-piece aluminum bracket | One-piece zinc casting | 42% cost reduction |
| Milled housing + standoffs | Integrated cast component | 55% faster assembly |
| Machined brass weight | ZA-8 die casting | 60% lower part cost |
❌ When Die Casting May Not Be Right
- <500 units/year
- Design changes frequently
- Extreme heat or chemical exposure
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📩 Want to Know if Your Part Is a Fit?
Get a free, no-obligation review.
Send your CAD file or part drawing to:
👉 ozarkdie.com/contact
We’ll assess feasibility, costs, and potential savings — no pressure.
