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Zinc Zamak Die Casting

As a One-stop Full-service Zinc alloy die casting parts manufacturer. KYLT provides Zamak 3 & Zamak 5 metal die cast parts as per customers' drawings or samples. We provide mold making, die casting, drilling, tapping, CNC milling or turning, and all kinds of surface finish treatment. Even finished assembly products can be also done here as per clients requirement.
Machining Methods:
Surface Finishes:
  • Zamak 3, Zamak 5, Others

  • OEM, ODM

KYLT - Zinc (Zamak) Die Casting Services

Zamak die cast bus inner door handle

KYLT, as a decades old zinc die-casting service supplier & manufacturer (commonly known as Zamak die-casting service company), provides complex zinc alloy die-castings with high precision, high strength, and good durability for various industries. This article will detail the entire process of converting zinc alloys from raw materials to fine components, allowing you to have a deeper understanding of KYLT's zinc alloy die-casting services.

Introduce Of Zinc/Zamak Die Casting Services

Zinc die-casting services are widely used in the manufacturing industry, providing a universal solution for the production of high-precision complex metal components. In this article, we will explore the complexity of this process, its widespread application, and the benefits it brings to various industries.

Understanding Zinc Die Casting

What is Zinc Die Casting?

Zinc Die Casting is a metal casting process that utilizes molten zinc to create intricate parts and components. It involves injecting molten zinc into a mold cavity, allowing it to solidify, and then ejecting the finished product. This method ensures high dimensional accuracy and a smooth surface finish.

The Zamak Advantage

Zamak, an alloy of zinc, is a preferred choice in die casting due to its excellent fluidity, corrosion resistance, and remarkable mechanical properties. Its ability to maintain tight tolerances and intricate shapes makes it ideal for a wide range of applications.

Applications of Zinc Die Casting

Automotive Industry

zinc alloy die cast forklift reflector holder

Zinc Die Casting plays a crucial role in the automotive sector, where lightweight yet sturdy components are essential for fuel efficiency and safety. It is used in producing parts like light parts, gears, inner door handle, and decorative elements.

Photo shows car zinc alloy die cast forklift reflector holder with black powder coating treatment.

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Electronics and Electrical

zamak die cast Fiber Coupler

In the electronics industry, where miniaturization is key, Zinc Die Casting shines. It is employed in manufacturing connectors, housing for electronic devices, and heat sinks due to its electrical conductivity and thermal properties.

Photo shows fiber coupler by zamak die casting with copper insert part.

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Household Appliances

Zinc Die Casting is also prevalent in the production of household appliances such as faucets, locks, and handles. Its ability to create aesthetically pleasing and durable products makes it a top choice.

Construction industry

Zinc die casting is used to produce various construction components, such as door handles, locks, and hinges. Zinc die casting is preferred in the construction industry due to its ability to produce parts with high strength, durability, and corrosion resistance.

Consumer goods industry

Zinc die casting is used to produce various consumer goods, such as toys, jewelry, and decorative items. Zinc die casting is preferred in the consumer goods industry due to its ability to produce parts with high precision and accuracy, as well as its excellent surface finish.

Medical industry

Zinc die casting is used to produce various medical components, such as surgical instruments, dental instruments, and medical devices. Zinc die casting is preferred in the medical industry due to its ability to produce parts with high precision and accuracy, as well as its excellent biocompatibility.

Furniture industry

Zinc die casting is used to produce various furniture components, such as handles, knobs, and decorative elements. Zinc die casting is preferred in the furniture industry due to its ability to produce parts with high precision and accuracy, as well as its excellent surface finish.

Sports equipment industry

Zinc die casting is used to produce various sports equipment components, such as golf club heads, bicycle pedals, and fishing reel parts. Zinc die casting is preferred in the sports equipment industry due to its ability to produce parts with high strength, durability, and corrosion resistance.

Lighting industry

Zinc die casting is used to produce various lighting components, such as lamp bases, shades, and reflectors. Zinc die casting is preferred in the lighting industry due to its ability to produce parts with high precision and accuracy, as well as its excellent surface finish.

KYLT Zinc Die Casting Capacity

We have hot chamber die casting machines and cold chamber die casting machines to produce zamak metal products.

Hot chamber zinc die casting machines are used to produce small size zamak parts. It is full automatically.

Cold chamber die casting machines are used to produce middle & big size zinc alloy parts. For low-volume orders, we can use manual operation. For quantity orders, working with auto robots can achieve automatic die casting.

Zinc (Zamak) Die Casting Parts Manufacturing Process

A successful zinc alloy die casting part requires several stages: Zinc die cast mold making, Zinc die casting, Machining, Surface finishes & treatment, Assembly etc. Zinc die casting mold or die and Zamak die casting are two key stages.

Zinc die casting mold making stage:

To bulid a new Zamak die casting part must have a good quality mold or die, In KYLT, we have 3 steps to maufacture a quality precision zinc injection mold:

  • First step: Communication of Zamak parts design and function

    In the first step, we will analyze the customer's zinc part drawing, add mold release angle, and prevent the product's structure can not be released from mold cavity. Try the best to insure zinc die casting part reach drawing required tolerance, to save machining cost. Of course, any changes to the drawings must be approved by the end-user。

If end-user only has zamak part sample, we can build 3D drawing as per client's sample. 

After both side confirmed drawing's details, we can start design and making molds.

  • Second step: Mold design and making

    In this step, it is necessary to consider the positions of injection gates, ensuring good filling of the zinc alloy while avoiding the gate position affecting the appearance or function of the product. If necessary, we will conduct mold flow analysis to provide assurance for the formation of zinc alloy products.

Zamak die casting mold made of steel, into which molten zinc will be injected. The mold is designed to the exact specifications of the desired component. CNC milling, CNC turning, WEDM, EDM etc precision machining methods be used in the Mold making process.

When the mold is ready, we will test the mold to check the mold's working function.

If there are die-casting defects in the sample, we will solve them by adjusting machine parameters or improving mold design.

If the cast zinc parts samples are ok, we will inspect the dimensions as per drawing requirements. Drilling, Tapping, Milling, Turning etc precision machining is used to ensure finished zamak parts with tight tolerance.

Whether as casted surface or plating, painting, powder coating, electrophoretic coating, shot blasting, and media tumbled.  Zamak cast parts surface finishes also will be ready in the sampling process.

  • Third step: Mass production

    After the end-user confirms samples, we can do mass production as per orders.      

Zinc Die casting Process

Step 1: Mold Ready & Checking

Zinc die cast mold is in a waiting state for production. Before we fix it in die casting machine, We must check the mold situation, such as the conditions of ejection pins, cooling water connectors and mold cavities etc.

Step 2: Melting the Zinc

Zinc is heated to its melting point and maintained in a liquid state within a furnace. This molten zinc is then ladled into a chamber.

Step 3: Injection and Cooling

The molten zinc is injected into the mold cavity under high pressure. Once injected, it rapidly cools and solidifies, taking on the shape of the mold.

Step 4: Ejection and Trimming

After cooling, the mold is opened, and the newly formed component is ejected. Excess material is trimmed, and the finished product is ready for use.

Zinc Die Casting Parts' Post-treatment

Post-treatment of Metal Zamak die-cast parts involves machining and surface treatment two aspects.

  1. Machining: Driller, Milling machine, Tapper, CNC machine, NC lathe etc machines be used to create the required dimensions as per the drawing.

  2. Surface treatment: Polishing, Sanding, Vibration grinding, Shot blasting is conventional surface treatment methods for zinc die casting parts. Powder coating, Painting, Plating, Electrophoretic coating be made as per customers' demand. We will adjust the processing sequence according to the requirements of different zinc alloy products.

  3. Assembly Services: if required, we provide assembly services. Plastic injection molding parts, Stamping parts, Bending parts, Welding parts, CNC milling parts, CNC turning parts, Aluminum die casting parts can be finished here and assemblied together as per clients demand.

Quality Control in Zinc Die Casting Parts

Maintaining quality is essential in zinc die casting. Stringent quality control measures ensure that each component meets the highest standards. In KYLT, quality control includes three aspects:

  1. Zamak alloy raw material's quality control: Standard Zamak 3, Zamak 5 alloy raw material is from famous chinese alloy suppliers. Each batch of zinc alloy ingots has corresponding material certificates to ensure their reliable quality. All Zind die casting parts only use new zamak alloy ingot.

  2. Zinc die casting process quality control: During the mold adjustment stage, check the zinc alloy parts for casting defects, cold spots, bulging, and missing materials. Ensure that the pressure, temperature, and other performance of the mold and die casting machine reach a good state, and start mass production after the molding of the die-casting parts is stable and good.

  3. Finished Zamak parts quality control: Micrometer, Go/No-go gauge, CMM etc be used to measure zinc parts machining dimensions. PANTONE Color cards and sealed samples are used for color comparison to ensure that the produced product color is consistent with the sample.

Advantages of Zinc Die Casting

Precision and Accuracy

Zinc Die Casting delivers exceptional precision, ensuring that even the most complex components meet stringent specifications.

Cost-Effective Production

Efficient use of materials and reduced post-processing requirements make zinc die casting a cost-effective choice.

Excellent Surface Finish

Components produced through zinc die casting exhibit a smooth surface finish, reducing the need for additional finishing processes.

Environmental Friendliness

Zinc is fully recyclable, making this process environmentally sustainable. Now, all Zamak alloys that we use are all lead-free alloys.

Why Choose KYLT's Zinc Die Casting Service?

Experience and professional knowledge

KYLT has decades of production experience in zinc die-casting. Our products are exported to countries and regions such as Japan, the United States, Europe, and Southeast Asia.

Equipment and Technology

Good equipment and technology are crucial for accuracy and efficiency.

Quality assurance

Our zinc die-casting service ensures the use of legitimate and qualified zinc alloy raw materials. The die-casting process does not use recycled materials, and production, machining, and testing are carried out according to drawing requirements.


With Zamak's versatility, KYLT zinc die-casting services are serving various aspects of the manufacturing industry. Provide high-quality, high-precision, and low-cost zinc alloy components for it.

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