Thinner Walls, Stronger Parts
Zinc alloys are stronger per weight than other materials. This means zinc castings may be produced with thin walls and less material and still be designed to optimize strength in ways other materials cannot. Aluminum’s cost per pound may appear less, but aluminum castings require more material and cost for the same strength.
Tighter Tolerances, Less Machining
Zinc alloys allow us to produce parts with tighter tolerances than aluminum or plastic. Not only is zinc’s precision better in general, but it allows us to design features that do not require more expensive machining as would be required by use of a different material.
Zinc alloys have high fluidity when the alloy is molten, producing a resilient casting with greater impact resistance and rigidity than its plastic and aluminum counterparts.
The surface of a zinc casting allows for great adhesion of many finishes to its surface, from powder coatings to plated finishes.
Zinc can be cast using a wide range of alloys to maximize strength, rigidity, or fluidity.
Longer Tool Life
A typical zinc mold can last 10 times as long as an aluminum mold because the die-casting process for zinc is much less corrosive to the mold than aluminum. If the tool cost is a large percentage of the production costs, using zinc instead of aluminum can provide significant savings.
The hot-chamber process has a much higher cycle-rate–more parts can be produced in the same amount of time, meaning less production cost. While aluminum is typically ladled into the mold, we are able to inject zinc into our molds.
Zinc is 100% recyclable, all byproducts of the casting process can be re-melted and cast again, unlike its plastic counterparts. Even painted and plated parts can be recycled and the zinc recaptured for reuse, making zinc a greener alternative.
Less Fuel Cost, Smaller Carbon Footprint
Zinc melts at around 800 degrees Fahrenheit, but aluminum requires 1200 degrees Fahrenheit. The extra heat required to cast aluminum means more fuel must be used in the production process.