Zinc Internal
Zinc Die Casting

Multi-Slide and Automated Conventional High Pressure Zinc Die Casting

Zinc Die Casting alloys are tough, reliable engineering materials that are cost-effective and endure longer than other alloy options. The unique alloy combination provides rigidness, strength, and increased value to die cast products. Zinc alloy processing is very economical due to the low melting temperature and it’s ability to produce thousands, or even millions, of parts with one set of Zinc Die Casting tools.

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Zinc Die Casting

Zinc Die Casting Benefits

From cost savings to longer product lifespan, zinc die casting can benefit your project in many ways.

  • Net Shape Casting
  • Long Tool Life
  • Fast Cycle Times
  • Low Melting Point
  • High Strength Properties
  • Thin Wall Capability
  • Good Creep Resistance
  • Superior Finish Characteristics
  • Excellent Conductivity
  • Sustainability



At Cast Products we cast a variety of different Zinc Alloys to meet your needs. Our complex blend of Zinc and other metals creates a low-cost, high-performing die-cast that will be ideal for your project and last for many years. Below are Zinc Alloys available for your casting needs.

ZAMAK 2 Zinc Casting Alloy

Zamak 2, a predecessor of the more widely used Zamak 3, has the highest strength and hardness in the zinc-4% aluminum (Zamak) alloy family. Because of its relatively high copper content (3%), it is about 25% stronger, as cast, than Zamak 3, and almost 10% stronger than Zamak 5, with higher hardness than either. The high copper content, however, results in property changes upon long term aging. These changes include slight dimensional growth (.0014in/in after 20yrs), lower elongation and reduced impact performance (to levels similar to aluminum alloys) for die cast products. It does, however, provide some interesting characteristics which may assist designers. Its creep performance is rated higher than the other Zamaks and Zamak 2 maintains higher tensile strength and hardness levels after long term aging. Also, preliminary investigations suggest Zamak 2 is a good bearing material and may eliminate bushings and wear inserts in die cast designs. But it does give up impact strength and because of this limitation, Zamak 2 is used only when the strength or hardness of Zamak 3 or 5 are not sufficient for long term end use. Zamak 2 is sometimes referred to as Kirksite and is the only alloy which is used for gravity casting; mainly for metal forming dies or plastic injection tools.

ZAMAK 3 Zinc Casting Alloy

Of all the zinc casting alloys, Zamak 3 is the most widely used, accounting for approx. 85% of all zinc casting tonnage. Its superb physical and mechanical properties, excellent castability and long term dimensional stability provide the basis for its broad usage. The ease with which it can be electroplated adds to the popularity of this alloy, with excellent finishing characteristics for plating, painting and chromate treatments. It is the “standard” by which other zinc alloys are rated in terms of die casting and is, therefore, the most widely available alloy from die casting sources.

ZAMAK 5 Zinc Casting Alloy

Most often, through casting design procedures, a Zamak 3 pressure die casting can be made to meet service or functional requirements. When this is not the case, especially where strength is concerned, Zamak 5 is the logical choice. Except for a nominal 1% copper addition, the chemistry of Zamak 5 is comparable to that of Zamak 3. This composition modification results in higher tensile strength and increased hardness, but with a sacrifice in elongation. Zamak 5 also has significantly better creep resistance than the other alloys in the conventional group. Zamak 5 is not as ductile as some of the other alloys, a factor to consider when post casting operations such as secondary bending, riveting, swaging or crimping are required. Because of Zamak 3’s wide availability, material specifiers often strengthen components by design modification instead of using Zamak 5. However, when an extra measure of tensile performance is needed, Zamak 5 castings are recommended. The alloy is readily plated, finished and machined, comparable to Zamak 3.

ZA-8 Zinc Casting Alloy

Of all the zinc alloys that can be cast in hot-chamber machines, ZA-8 is the most creep resistant (three times that of Zamak 3) and is the strongest and hardest, with the exception of Zamak 2, which is very similar in performance. It is used principally in structural or highly stressed applications. In spite of its relatively high aluminum content, it can be electroplated using conventional plating techniques and finished using standard procedures for Zamaks. When the performance of standard Zamak 3 or Zamak 5 is in question, ZA-8 is often the die casting choice because of high strength and creep properties and efficient hot chamber castability.

Zinc Die Casting Equipment

Since 1966, Cast Products, Inc. has been a North American leader in design and full- scale manufacturing of precision zinc die cast components. Although the majority of our current production utilizes the Multi-Slide die casting process, we are equally strong in the manufacture of larger, Conventional Hot-Chamber die casting parts. We have 30 Hot-Chamber die cast machines ranging in size from 2X2, 4X4, 6X6, 8X8 & 80 Ton to meet your production requirements.

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Zinc Die Casting
  • 1 Model 22 “NT” Techmire Machines
  • 1 Model 44 “NT” Techmire Machines
  • 2 Model 44 “NTX” Techmire Machines
  • 2 Model 66 “NT” Techmire Machines
  • 10 Model 66 “NTX” Techmire Machines
  • 10 Model 88 “NTX” Techmire Machines
  • 4 Conventional Die Casting Machines ranging from 25-80 tons including 2 Frech W80 conventional automated machines
Drilling and Tapping Equipment

Over 50 Machines ranging from multi-head tap machines to production lathes

Tool Room Equipment
  • 5000 square foot on-site integrated die fabrication department
  • 1 Creative Evolution HSD-500 High Speed CNC machine
  • 1 HAAS VM3 CNC machine
  • 1 HAAS VF2 CNC machine
  • 1 HAAS Super mini high speed CNC machine
  • 1 Charmilles Roboform 22 EDM Machine
  • 1 Agie/Charmilles Form 30 CNC EDM Machine
CAD/CAM Software
  • Solidworks 2016
  • AutoCAD 2012
  • Mastercam “X8“
  • Cimatron E13
  • Magmasoft 5.0
Metal Finishing
  • 1 Viking Model CB1212 Continuous belt feed blast machine
  • 1 Goff 6 Cubic foot barrel shot blast machine
  • 1 Goff 3 Cubic foot barrel shot blast machine
  • 4 Sweco Vibratory Finishing Tubs
Quality Equipment
  • Brown & Sharpe Global Advantage 7107 DCC CMM System
  • Brown & Sharpe Micro-Hite CNC CMM
  • Each CMM is loaded with Hexagon Metrology PC-DMIS CAD++ Software
  • Brucker Q4 Tasman 200 Optical Emission Spectrometer
  • Optical Gaging Products Opticom Qualifier 14B Comparator
  • A complete line of inspection instruments ranging from handheld micrometers and calipers to digital drop indicators. We can build custom test equipment for pressure and load failure testing.

Advantages and Benefits of Zinc Die Casting


What is a Zinc Alloy?

Zinc Alloys refer to any metal composed of at least two elements, with one being Zinc. These resulting metal alloys are more beneficial than just a singular metal. Zinc metal alloys are more uniform in nature and have improved physical, chemical, electrical, and corrosion-resistant properties. For these reasons, Zinc alloys stand out as a preferred choice in metal alloys available for Die Casting projects.

Why should you choose Zinc Die Casting for your next project?

There are several reasons why Zinc Die Casting is often chosen for die cast projects. That’s because it is one of the more versatile die cast metals available. With Zinc Die Casting you can achieve higher precision, casting to net-shape, with reduced tooling costs in comparison to other common die cast metals like aluminum or magnesium. Using Zinc Die Casting gives products a wide range of preferred physical and mechanical properties, along with superior finishing characteristics, while being the most economical alloy to cast.

Today, choosing Zinc Die Casting can reduce your overall project costs. Zinc has a low melting temperature which equates to less energy usage in processing.  Zinc alloy properties also make them less aggressive on tooling which means dies last up to 10 times longer than aluminum, and up to 5 times longer than a die with magnesium. Longer lifespans of production tooling mean fewer repairs, less downtime, and greater part production.  Greater efficiency with lower capital investment.

Zinc Die Casting is ideal for projects within the building, industrial, electronic, recreational, and automotive industries.  Zinc Die Casting alloys are tough, reliable engineering materials that are cost-effective and endure longer than other alloy options. The unique alloy combination provides rigidness, strength, and increased value to die cast products. Zinc alloy processing is very economical, and environmentally friendly providing users the ability to produce millions of parts with one set of tools.  Contact us for more information on what Zinc can do for you.

Recent History of the US Zinc Die Casting Industry


Over the last 20 years, the U.S. has seen a structural supply chain shift in manufacturing, including the Zinc Die Casting industry. Huge amounts of products shifted from manufacturing on US shores to abroad; China being the main benefactor. Chinese manufacturers were able to offer lower prices for not only Zinc die castings, but also tooling, machining and assembly, resulting in lower purchasing costs for manufactured zinc products.

Today, as an industry, Cast Products have studied offshoring significantly to help determine how we can be competitive on this global stage. We have also recently seen how geopolitical risks are affecting this supply chain, from the onset of the Covid-19 pandemic to the war between Ukraine and Russia. Due to these factors, there is an ongoing movement to reshore manufacturing domestically, like the Zinc Die Casting industry.

The Real Cost of Offshoring Zinc Die Casting – Calculating TCO (Total Cost of Ownership):

A key factor in offshoring manufacturing is considering the true cost of purchasing from non-US sources. Total Cost of Ownership (TCO) is a financial term used to help buyers and owners determine all the costs of a product, not just the purchase price. These additional costs may include:

• Goods damaged during transport
• Defects
• Travel costs
• Emergency Air Freight Costs
• Currency fluctuations
• Inventory carrying costs
• In addition, there are less quantifiable issues such as no credit terms, communication issues, inflation, etc.

Efforts have been made to show the difference in these costs, with the purchasing costs on average being only 77% of the true cost of offshoring products (Source: Reshoring Initiative).

Research has also been done on this subject specifically for Die Casting. Two reports entitled “China Has Lost Its Cost Advantage in Die Casting” parts 1 and 2 (Bill Downey), show summaries of surveys to Original Equipment Manufacturers (OEMs) which give insight as:

• Why the die casting industry left our shores
• Savings that were realized by going offshore
• The premium OEMs were willing to pay for US parts.

Using data trends and calculations (including rising inflation, transportation costs, etc), the report pointed out approximately when parts made in the U.S. would be competitive with Chinese parts. According to the report, that parity date occurred in 2012. When calculating the TCO, offshoring your Zinc die casting and tooling, isn’t a smart business move.

It’s Time to Choose a US Partner for Zinc Die Casting

The improvements made in our Zinc die cast manufacturing facilities over the last 20 years, and our current capabilities and services can match or exceed the level received from off-shore sources. View our new technology in alloys, automation, and engineering to learn the advantages of Zinc Die Casting from US manufacturers like Cast Products.

Cast Products is your partner, and we look forward to the opportunities to provide you with superior Zinc Die Casting and Tooling services.

Frequently Asked Questions About Zinc Die Casting and Cast Products

What is the most common alloy used in Zinc die casting?

Zamak 3 is the most common alloy used in the industry. There are other alloys like Zamak 2, Zamak 5, and ZA-8 available to fit a variety of applications.

What is the estimated tool life of a die-cast tool for Zinc?

We estimate approximately 1MM shots before a tool requires replacement. This can vary depending on the complexity of the tool and casting.

What finishes can be applied to a Zinc die casting?

Zinc is one of the most flexible cast alloys to finish. Options include plating (decorative & functional), painting (wet & powder) & E-coat.

Can Zinc castings be anodized?

Anodizing on Zinc alloys is not recommended as it provides an inconsistent surface finish.

How do I reduce porosity in my Zinc die castings?

Work with the Cast Products engineering team at the time of product development. We use the latest Flow Simulation software (Magmasoft) to develop the most efficient material flow within the tool.

Can you weld Zinc die castings?

No. Zinc alloys cannot be welded as the heat destroys the casting.

Do Zinc alloys provide conductivity and shielding properties?

Yes. Zinc is highly conductive and often used in applications requiring EMI or RF shielding.

How is flash removed from a Zinc casting?

Flash can be removed from a Zinc casting through thermal deburr, vibratory deburr, and shot blasting.

Does Zinc die cast parts require a trimming operation?

In most cases, secondary trim operations can be avoided. At Cast Products, we focus on flash free casting which eliminates the need for trimming.

How thin of a wall can you allow in a Zinc casting?

The flow properties of the common cast alloys provide the ability to cast thin walls. Thickness is dependent on part design so please contact our Zinc casting Engineering team to discuss.

What is the melting temperature of Zamak alloy?

The melting point of Zamak Zinc Alloys is 787 degrees Fahrenheit.

Are Zinc alloys environmentally friendly?

Yes. Zinc is a naturally occurring element and is easily recyclable. Because of its low melting temperature, Zinc processing uses less energy than other die-cast alloys.

How do I choose the right Zinc alloy for my application?

Please follow this link for a Zink alloy specification sheet, or contact us at sales@castproducts.com

How long have Cast Products been in business?

We were founded in 1966 and continue to provide top quality Zinc die casting and tooling.

Do Cast Products recycle?

Yes. At Cast Products, we recycle our gates, runners, and overflows.

What size of parts can Cast Products produce?

Our part range is from a few grams to over a pound.

Is there a volume requirement to quote?

Cast Products is a high-volume die caster with volumes from several thousand to millions of parts annually.

Do you build your own tools?

Yes. We have an internal tool shop where most of our tools are built.

Can you support transfer tools?

This is discussed on a case-by-case basis. A transfer will be dependent on tool size, type, and condition. Please contact us to review.

What secondary operations can CPI provide?

We can provide drill, tap, and mechanical assembly.

Can you provide prototypes?

CPI has options for prototypes depending on our customer’s requirements. We can provide 3D printed plastic prototypes, spin, and investment components, or build single cavity tools for low volume and functional review.

What alloys do Cast Products offer?

We provide a variety of Zinc Alloys, including Zamak 2, Zamak 3, Zamak 5, ZA-8

Does Cast Products ship outside the USA?

We currently ship to Mexico, Canada, and the USA.

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Cast Products, Inc.


4200 N. Nordica
Norridge, IL 60706

(708) 457-1500

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Proudly Made in the U.S.A.