By Ozark Die Casting
Zinc Die Casting: High Precision at High Speed
Zinc die casting injects molten zinc alloy into a steel mold under pressure — creating complex, accurate parts with minimal machining. Ideal for large-volume production, it offers unmatched efficiency, dimensional stability, and surface finish.
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How the Process Works
1. Design Review – We evaluate wall thickness, draft angles, geometry
2. Tooling – A hardened steel die is built (one-time investment)
3. Injection – Zinc alloy is injected at 1,000–5,000 PSI
4. Cooling & Ejection – Mold is water-cooled, part ejected automatically
5. Finishing – Trimming, optional CNC, surface treatments, inspection
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Why Choose Zinc?
✅ Tight Tolerances – ±0.001” repeatable with proper tooling
✅ Strength – ZAMAK 5: 31,000 PSI tensile strength
✅ Thin Walls – Down to 0.020”
✅ Excellent Surface Finish – Ideal for coatings/plating
✅ Fast Cycle Times – 3–30 seconds per part
✅ Corrosion Resistant – Especially with proper alloy/finishing
✅ Eco-Friendly – 100% recyclable, low melting temp (787°F)
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Common Alloys
At Ozark, we primarily use ZAMAK-series alloys, developed for high-performance casting. Here’s a quick breakdown:
| Alloy | Traits | Best Use |
|---|---|---|
| ZAMAK 3 | Most common, stable, smooth finish | General components |
| ZAMAK 5 | Higher strength/hardness | Functional parts |
| ZA-8 | Strongest, wear resistant | Gears, housings |
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Ideal for These Applications, we currently produce parts for these following:
- Appliance housings
- Electric motors & enclosures
- Fuel & gas system components
- Fiber optics & telecom
- Industrial housings & controls
- Precision brackets & mounts
- Industrial, commercial and home use tools
- HVAC
- Automation
- Components for various hobbies
- Ammunition
How the Process Works
Use it if:
- Volume > 500 parts/year
- Complex geometry or tight tolerances
- Smooth cosmetic finish required
- Cost-sensitive secondary operations
Design Tips for Castability
- Add 1–2° draft angles
- Maintain uniform wall thickness
- Use fillets (not sharp corners)
- Minimize undercuts
- Consolidate multiple parts into one
Why Engineers Choose Ozark
With 45+ years of experience, Ozark Die Casting delivers:
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Expert design consultation
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ISO 9001:2015 certified U.S. production
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Automated, lean operations
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Proven results from prototype to full scale
📩 Contact us for a free consultation
ozarkdie.com/contact
