By Ozark Die Casting
Still Machining High-Volume Parts? You May Be Leaving Money on the Table.
Machining is ideal for prototyping and small runs. But when your production scales, zinc die casting often outperforms — delivering equal precision, better consistency, and 30–60% lower costs per part.
Ozark Die Casting has helped dozens of companies make the switch. Here’s what you need to know:
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What Is Zinc Die Casting?
A process where molten zinc is injected into a steel mold under high pressure — producing parts that often require no additional machining.
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Ideal for: Appliances, motors, fuel systems, optical housings
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Alloys we use: ZAMAK 3, 5, ZA-8
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Key advantages: Tight tolerances, high strength, excellent surface finish
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Zinc vs. Aluminum Die Casting
| Factor | Zinc | Aluminum |
|---|---|---|
| Tool Life | ~1 million shots | ~100,000 shots |
| Tolerances | ±0.0005–0.003” | ±0.003” |
| Finish | Paint/plating-ready | Paint/anodize-ready |
| Design | Great for thin walls, complex shapes | Better for high-heat, lightweight parts |
Real-World Savings Example
A client machining 6061 aluminum brackets (10,000 units): – Machined cost: $6.00/part – Cast cost: $2.35/part – Savings: 60% per part — with identical tolerances and better consistency
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Why Is Die Casting Cheaper?
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Fast cycle times
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Minimal material waste
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Fewer secondary operations
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One-time tooling cost amortized over high volumes
Die casting pays off at ~5,000+ units/year — often even sooner.
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Is Your Part a Good Fit?
✅ 500+ units annually
✅ Aluminum, brass, or similar materials
✅ Wall thickness: 0.040–0.120”
✅ Complex geometry
✅ Looking to reduce cost
We help you optimize the design for castability.
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Why Zinc?
- Tight tolerances
- Dimensional stability
- Thin-wall casting
- Great finish for coatings/plating
- Highly recyclable & low energy
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Case Study: HVAC Manufacturer
- Replaced high-cost brass with ZA-8
- Designed multi-cavity die
- Reduced post-processing
- Cut part cost by 60%
- Improved lead times & quality
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When to Stick with Machining
- Early prototypes
- Ultra-tight tolerances (<0.0001”)
- Very low volume (<100 units)
- Complex internal geometries not castable
We offer CNC services in-house for hybrid needs.
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Our Process
- Part Review — Send us a drawing or part
- Design Feedback — We help optimize for casting
- Tooling & Samples — First articles inspected to spec
- Production — Fast, consistent, scalable
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Let’s see what die casting can do for your bottom line.
With 45+ years of experience, Ozark Die Casting can help you reduce costs, simplify production, and scale with confidence.
📩 Free part evaluation: ozarkdie.com/contact
