Zinc Casting Services
Frigate offers reliable zinc casting solutions using custom die molds. From mold design to component manufacturing and packaging, we have all the aspects of casting.Â
Our Clients
Advantages of Zinc Casting Services
Easily Plated
Zinc offers reliable adhesion, making it suitable for finishing processes such as planting, powder coating, and painting.
Excellent Conductivity
Zinc provides extensive electrical and thermal conductivity compared to many other metals.
Long life with minimal maintenance
Zinc alloys put less stress on the die during casting, which helps extend the die's overall service life.
Excellent RFI/EMI shielding capabilities
Zinc housings with net-shaped designs and thinner walls offer excellent shielding properties.
Efficiency and precision with an advanced mechanism for clamping
Our die-casting molds have advanced clamping systems for reliable and high-quality performance. We use computer techniques to perfectly size the hinges, ensuring they work quickly and with better precision. The molds are made from ductile iron and cast steel, which provide strong and sturdy construction, reducing the risk of breaks during normal use. We’ve also reinforced the head, middle, and tail plates and added a gantry structure to increase the overall strength and stiffness of the mold. This careful design ensures that our production runs smoothly and accurately.Â
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Our Zinc Casting Process
First, a steel mold is made, shaped to match the part you want to create. This mold is designed to withstand the high pressure and temperature of the molten zinc.Â
Zinc is heated until it melts into a liquid form. This molten zinc is then ready to be poured or injected into the mold.Â
In the die casting process, the molten zinc is injected into the mold under high pressure. This ensures that the zinc fills all the tiny details of the mold, creating a precise part.Â
Once the mold is filled, the zinc is allowed to cool and solidify. This cooling process is quick, and as the zinc hardens, it shapes the mold.Â
After cooling, the solidified part is ejected from the mold, which can then be reused for the next casting.Â
Finally, the cast part may undergo finishing processes like trimming, polishing, or coating to remove imperfections and give it the desired appearance and functionality.Â
Zinc Casting Materials
Zinc casting materials comprise zinc alloys, known for their excellent casting properties, durability, and versatility. These materials vary in terms of strength, hardness, weight, and the desired surface finish.Â
It is a family of zinc alloys made of aluminum, magnesium, and copper. They are widely used in die casting due to their strength, flexibility, and corrosion resistance.Â
- Zamak 2: Known for its high strength and hardness, Zamak 2 is often used for gravity casting and is sometimes called Kirksite. It's a good choice for durable parts and may even eliminate the need for bushings in some designs.Â
- Zamak 3: It offers a balanced combination of mechanical and physical properties, making it suitable for various applications. It has excellent castability and maintains long-term dimensional stability.Â
- Zamak 5: This alloy provides higher hardness and strength than Zamak 3, making it ideal for applications that require more robust parts. It is the most popular zinc alloy in Europe.Â
- Zamak 7: A high-purity version of Zamak 3, Zamak 7 has lower magnesium content, improving fluidity, flexibility, and surface finish in castings. It's often used when a high-quality surface finish is needed.Â
ZA alloys contain higher aluminum content than Zamak alloys, and they have different properties that can be beneficial for specific applications.Â
- ZA8: Containing around 8.4% aluminum, ZA8 is the only alloy that can be hot-chamber die-cast. This makes it a good choice when a high aluminum content is needed in a hot-chamber process.Â
- ZA27: With approximately 27% aluminum, ZA27 is much stronger and lighter than Zamak alloys. It is used in applications that require high strength-to-weight ratios and good wear resistance.Â
Kirksite is a zinc-based alloy sometimes used to make tools, molds, and dies. It's known for its good wear resistance and can be used for low-volume production runs.Â
ZnAl alloys, like ZA8 and ZA27, are known for their strength, lightweight, and good wear resistance. It is commonly used in industries where higher performance is required than what standard Zamak alloys can offer.Â
Frigate Provides Continuous Commitment to Quality
Quality is our top priority. We use extensive quality control measures to ensure your zinc die-cast parts meet the highest standards. We also use high-precision tools to inspect every part we make. This means you can trust your parts to meet or exceed industry standards. We pay attention to every detail so that you get the best results every time.Â
Compliance for Zinc Casting Services
Frigate follows advanced industry standards in Zinc Casting. Our processes use precise die-casting technology to ensure high accuracy and minimal porosity. We apply custom gating systems to optimize metal flow, reducing defects and ensuring uniform thickness. High-quality zinc alloys, like ZA-8 and ZA-12, are selected for enhanced strength and corrosion resistance. Automated inspection systems measure dimensions to micro tolerances, ensuring consistent quality. Â
Certification number: 12345-QMS-001.Â
Certification number: 67890-RoHS-002.Â
Certification number: 11223-ASTM-003.Â
Certification number: 44556-REACH-004.Â
Certification number: 78901-EPA-005.Â
Certification number: 66778-ANSI-006.
Tolerance for Zinc Casting Services
Tolerance for overall part dimensions, including length, width, and height.Â
Tolerance for variation in wall thickness across the casting.Â
Tolerance for surface flatness in relation to a reference plane.Â
Tolerance for the straightness of edges or linear features.Â
Tolerance for round features such as holes, bores, or circular edges.Â
Tolerance for angular deviations in casting features, like corners or surfaces.Â
Tolerance for surface finish quality, indicating the smoothness of a casting's surface.Â
Tolerance for movement or misalignment of internal cores in multi-cavity molds.Â
Tolerance for the positional accuracy of features relative to the part's datum or reference points.Â
Tolerance for threaded features, ensuring proper fit and function with mating parts.Â
Tolerance for features that must be perpendicular to reference surfaces or other features.Â
Tolerance for concentricity of circular features like holes, ensuring alignment to a central axis.Â
Tolerance for the variation in the surface profile relative to a defined reference line or surface.Â
Tolerance for the circularity or straightness of a feature when rotated about an axis.Â
Tolerance accounting for the shrinkage of the material as it cools after casting.Â
Tolerance for variation in material composition, ensuring uniformity in alloy proportions.Â
Quality Testing Standards for Zinc Casting Services
Detects internal porosity, ensuring structural integrity by revealing air pockets or voids inside the casting.Â
Examines the microstructure of the zinc alloy to evaluate grain size and uniformity, which affects mechanical properties.Â
Detects surface cracks and discontinuities by applying a fluorescent dye to reveal any flaws in the casting.Â
Assesses the casting's ability to withstand repeated stress cycles without failure, simulating real-world usage.Â
Measures the ability of the casting to resist sudden, high-impact forces, testing its toughness and brittleness.Â
Evaluates the casting's ability to resist deformation under sustained stress or load over time at elevated temperatures.Â
Measures the casting’s ability to conduct heat, important for parts exposed to high temperatures or thermal cycling.Â
Measures the material's ability to conduct electricity, useful for casting parts with electrical or thermal conductivity requirements.Â
Assesses the material’s ability to withstand corrosive environments by simulating exposure to saltwater or humid conditions.Â
Measures the material's stiffness, which is critical for applications requiring rigidity or deformation resistance.Â
Evaluates the casting’s ability to maintain its shape under temperature changes, important for precision applications.Â
Measures the hardness of the surface layer, determining wear resistance for parts exposed to friction or abrasion.Â
Determines the density of the zinc alloy casting, ensuring it meets the required specifications and material properties.Â
Assesses the ease and quality of welding on the casting, important for parts requiring assembly or further machining.Â
Measures how the casting deforms under applied load, ensuring it meets performance requirements under operational stresses.Â
Metal Prototypes and On-demand Production for Automotive Components
Zinc casting plays a vital role in the automotive industry because of its durability, strength, and ability to create complex shapes. Zinc alloys like Zamak are known for their high impact resistance and precision, making them ideal for intricate automotive parts like gears and brackets. Â
We ensure that our process is cost-effective, allowing for efficient high-volume production. We also produce lightweight components that help improve vehicle performance and fuel efficiency. Frigate’s zinc casting services offer excellent surface finishes and corrosion resistance, ensuring long-lasting quality and reliability in automotive applications.Â
Industries We Serve
What You Get
↓ 7-8%
OPS COST
↓ 2-3%
COGM
3X
Aggregation
↑ 25%
Machinery Utilisation
↓ 50%
Expedition
↑ 30%
Frigater Revenue
Partner with Frigate for Custom Zinc Casting Solutions
Zinc die casting at Frigate is a top choice for creating high-quality, durable parts. Using the latest technology and expertise, we produce reliable products for all kinds of needs. Whether for industrial, commercial, or consumer uses, zinc casting works well for making both small, detailed designs and large quantities of parts. It’s perfect for a wide range of shapes and sizes, delivering excellent results every time.Â
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Having Doubts? Our FAQ
Check all our Frequently Asked Question
Zinc forging is ideal for high-strength parts because the process compacts the Zinc under extreme pressure, which makes the metal denser and stronger. This high density gives the forged parts excellent mechanical properties like impact resistance, toughness, and durability, especially compared to cast or machined zinc parts.Â
Precise temperature control is critical in zinc forging. Zinc has a low melting point (about 420°C), and overheating can cause the metal to lose its desired properties. Maintaining the right temperature during forging ensures the Zinc remains malleable without becoming too soft, leading to a final product with better dimensional accuracy and surface finish.Â
Grain flow refers to how the metal's internal structure aligns during the forging process. In zinc forging, this grain flow follows the shape of the forged part, enhancing strength along specific stress points. This means the forged part can handle more stress and has better fatigue resistance compared to cast or machined parts, where grain flow is disrupted.Â
Zinc forging creates near-net-shape parts, meaning the forged product is close to the final required dimensions. This reduces the need for extensive machining, which normally produces waste. Additionally, the Zinc used in forging can be recycled easily, further minimizing material loss and promoting sustainable manufacturing.Â
Yes, zinc forging can produce complex geometries with tight tolerances. The process allows precise control over the shape and dimensions of the part due to the malleability of Zinc and the high-pressure forces applied during forging. This makes Zinc forging suitable for intricate components in industries like automotive, electronics, and aerospace.Â
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LOCATIONS
Global Sales Office
818, Preakness lane, Coppell, Texas, USA – 75019
Registered Office
23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.
Operations Office
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ã…¤
