This article explores the significant role of zinc die casting in the electronics industry also highlighting its advantages and applications.

Zinc die casting is a process where molten zinc alloys are injected into a steel die that has been finished with lubricant. Due to their flexibility, impact strength and low melting point, zinc alloys are used for parts production for various industries including the electronics industry. In addition, the casting process takes place at a lower temperature due to the low melting point of the material. This makes the hot chamber die casting process convenient compared to other technologies. In addition, hot chamber die casting is a process th at promotes longer die life and faster recovery time compared to other die casting compatible materials.

Applications of zinc die casting products in various industries

Zinc die casting parts are used in various industries due to its durability and strength. Below is a list of industries / sectors in which zinc die casting components are being commonly used because of its various advantages and benefits that it provides to the manufacturers as well as to the users of the final product.

• Home appliances

Zinc casting is used to make a variety of household items including belts, furniture inserts, door handles and locks. Its strength and dimensional stability make it ideal for use in home appliances.

• Automotive sector

Zinc castings are used in the production of interior fittings in automobiles. These castings are preferred over aluminum because they are stronger. Examples of automotive zinc alloy castings include bearings and steering.

• Mechanical sector

Zinc die casting parts are used to produce engine parts used in mechanics. The properties of zinc, such as corrosion resistance and hardness make it a more desirable option than aluminum.

• Electronics

Zinc die castings are used in the production of electronic components such as energy regulators, switches, ceramic resistors and wall clocks. The zamak – 3 alloy is best suited for these parts because it offers dimensional stability.

Why is die casting used in electronics industry?

Die casting is used in the electronics industry for its ability to produce complex, highly detailed and accurate metal parts in large quantities. The process creates a uniform and consistent parts with a smooth surface finish which is important for housing delicate components. Additionally, die casting can be used to produce parts with intricate shapes, thin walls and tight tolerances which are often required in electronic applications. The process also offers the option of incorporating internal voids and passages for electrical and mechanical connections.

Zinc die casting and aluminium die casting are used to make electronic products. Zinc die casting is used in applications that require high mechanical strength such as connectors and terminal blocks. Zinc has good castability and can be easily formed into complex shapes making it well – suited for die casting. Additionally, zinc offers good electrical conductivity and good corrosion resistance which are important factors in the electronics industry.

Zinc die casting in electronics parts

In the electronics industry, zinc die casting is used to produce various parts. Some of them are mentioned below:

• Connectors and housings

Zinc die cast connectors and housings are widely used in electronic devices to provide robust and reliable connections. The high precision achievable through die casting ensures that these components meet the demanding specifications of modern electronic devices.

• Enclosures for electronic devices and components

Electronic device enclosures play a crucial role in protecting internal components from external elements such as dust, moisture and physical damage. Zinc die – cast enclosures offer a durable and cost – effective solution ensuring the integrity and longevity of the enclosed electronic systems. Zinc’s excellent electrical conductivity also provides good EMI, RFI and ESD shielding.

• Heat sinks

Zinc has a lower thermal conductivity compared to pure aluminium, however if we compare the thermal conductivity between die-cast zinc alloy and die cast aluminium alloy we can see that the thermal conductivity is very similar. Zinc remains a valuable material in many industries. Zinc’s excellent fluidity permits the production of thinner, finer and closely spaced fins that provide a larger surface area but less volume. Zinc is also stronger, stiffer and tougher than aluminum, die-cast aluminum and magnesium. Zinc also offers strong resistance to impact and great flexibility. Some of these characteristics makes zinc an ideal choice for manufacturing heat sinks.

• Chassis and frames

Chassis and frames provide structural support for various electronic components within a device. Zinc die – casting for chassis and frames offers a lightweight yet sturdy solution contributing to the overall structural integrity and mechanical stability of electronic devices.

• Bases and mounting plates

Bases and mounting plates are essential components for securely positioning electronic devices and ensuring stability. Zinc die – cast bases and mounting plates provide a strong and reliable foundation allowing for secure installation and optimal functionality of electronic equipment.

• Handles and knobs

Handles and knobs are user interface components that enhance the ergonomics and usability of electronic devices. Zinc die – cast handles and knobs provide a combination of durability and design flexibility contributing to a positive user experience in various electronic applications.

• Electromagnetic interference shielding components

Zinc alloys possess electromagnetic interference shielding properties making them suitable for components that require protection from external electromagnetic radiation. This is particularly important in sensitive electronic devices where interference can lead to malfunctions.

• Brackets and supports

Brackets and supports play a vital role in securing and stabilizing internal components within electronic devices. Zinc die cast brackets and supports offer reliable structural support ensuring the proper alignment and functionality of various elements within electronic systems.

• Cable glands

Cable glands are essential for providing secure entry points for cables while maintaining environmental seals. Zinc die – cast cable glands offer robust protection against moisture and other external factors ensuring the integrity of electrical connections in electronic devices.

• Bezels and trim pieces

Bezels and trim pieces contribute to the aesthetic appeal of electronic devices while providing functional features. Zinc die – cast bezels and trim pieces offer a combination of design versatility and durability enhancing the overall appearance and user interface of electronic equipment.

Benefits of Die Casting for Electronics

• High accuracy and dimensional stability

Zinc die casting in electronics industry results in consistent and reliable parts that are produced because of its high accuracy and stability in dimensions.

• Enhanced mechanical properties

Zinc alloys exhibit excellent mechanical properties including high strength, durability and corrosion resistance. Zinc is a versatile material with good strength, corrosion resistance, and stability. These characteristics make zinc die cast components ideal for electronic applications where reliability and longevity are paramount.

• Cost effective production

The efficiency of the die casting process contributes to the cost – effective production. Manufacturers benefit from reduced material wastage, shorter production cycles and lower energy consumption making zinc die casting an economically viable option.

• Design flexibility

Zinc, with its complex and intricate melting point, can be cast into a variety of shapes making it a popular option for many different designs.

• Precision and complexity

Zinc die casting enables the production of highly intricate and complex components with tight tolerances. This is crucial in the electronics industry where small, precisely engineered parts are often required for devices such as smartphones, laptops and other electronic gadgets.

• Surface finish

Zinc die casting is ideal for applications that require a smooth surface finish, which can be easily painted or plated and thus eliminates the need for additional finishing operations.

• Fast production

Zinc casting is an efficient and rapid production method making it well suited for large scale manufacturing.

Conclusion

Zinc die casting has emerged as a key player in the electronics industry offering a winning combination of precision, cost effectiveness and superior mechanical properties. As electronic devices continue to advance in complexity and miniaturization, the role of zinc die casting is likely to expand further that will also contribute to the evolution of the electronics landscape. Manufacturers and engineers are embracing this versatile manufacturing process to meet the growing demands for high quality electronic components in the digital age.

Also, as industries increasingly are prioritizing sustainability and environmental responsibility, zinc die casting also presents itself as an eco – friendly solution. With its recyclability and minimal waste production during manufacturing, zinc die casting itself aligns with the goals of sustainable production practices. Furthermore, the versatility of zinc alloys allows for the creation of different varied designs and shapes which helps in catering to the evolving preferences of consumers in the electronics market. As a result, the future of zinc die casting appears to be promising and it also has a potential to play an integral role in shaping the next generation of electronic devices while meeting the demands of both manufacturers and the consumer.

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The component in question is linked to the safety of the vehicle’s driver and passengers. Due to its very nature, it requires a maximum tolerance of a few thousandths compared to the required weight of 6 grams. Such a tight tolerance level is challenging to be respected 100% in producing die-cast parts.

Bruschi’s R&D team and technical office took the lead in developing a pioneering project in the sector. Leveraging software development and cutting-edge technologies, they overcame the common limitations of die-casting production and met the customer’s demand.

Therefore, the mass production of zinc pieces smaller than a €1 coin was guaranteed, respecting the tolerance specifications provided by the customer.

Bruschi designed and implemented a fully automated production process to ensure precision and quality. This process involves the use of robots equipped with precision grippers capable of extracting the die-cast components from the molds. A camera placed on the machine allows the robot to independently verify the presence of all the pieces inside the mold, dismantle them, and place them on a precision scale for quality assurance.

Any pieces that do not meet weight standards activate a reject system.

This is an example of how technological progress and engineering skills make it possible to satisfy the market’s needs, overcoming production limits that only a constantly evolving company can overcome.

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In recent times, automotive manufacturers are more focused on manufacturing lightweight automobiles without affecting durability of the vehicles. Therefore, die casting is one of the most valuable techniques adopted by the manufacturers for creating automotive parts. The number of die cast parts used for automobiles continues to rise daily. Some of the main reasons for the increase in demand of die casting by the manufactures are:

Increased precision, efficiency and cost effectiveness

Die casting is a technology that helps in increasing precision, efficiency and cost effectiveness of the automobiles / vehicles that are getting manufactured by using die casted products or components. Die casting is also one of main reason behind numerous automotive advancements that are witnessed by all of us. With the ability to mold materials such as zinc, aluminum and magnesium alloys, die casting unlocks various other opportunities that helps in elevating vehicle performance boosting in an overall growth of automotive industry.

Helps in fuel efficiency

The inclusion of die cast components in the automobiles, mainly in engines, also helps in fuel efficiency as the overall weight of the vehicle reduces when die casted components are used which also results in lower emissions resulting in reduction of pollution and better vehicle performance that helps in production of more units effectively and efficiently.

Increased automation and flexibility

The popularity of automotive die casting is increasing day by day all over the globe due to the high use of advanced technology in almost every industry. All the process becomes more effective and productive when the production process is automated. Moreover, die casting technique helps to create parts with complex shapes and sizes easily which ultimately makes the installation process smoother.

As discussed above, die casting helps to produce parts with complex shapes with high durability and improved aesthetic appearances. Following are some of the parts / systems from wide variety of applications of die casting for automobiles that includes:

• Engine parts
• Mounting brackets for electric motors and stepper motors
• Electronic covers for gearbox
• Sensor and airbag housings as active safety mechanisms
• Fuel intake parts
• Air conditioning systems
• Mounting brackets for stepper motors
• Retractor spools for seatbelts
• Transmission components
• Sensors
• Chassis components
• Durable power steering and braking systems

Advancements in die casting technology

As automotive manufacturers strive to stay at the top of innovation and adapt to new technologies, die casting technology has evolved to meet the growing demands of the industry which also helps the manufacturers to product the vehicles with the new technology that also helps in customer satisfaction. Some of the main advanced die casting techniques are playing a crucial role in achieving higher levels of precision and efficiency in automotive industry such as:

1. High pressure die casting

High pressure die casting involves injecting molten metal into a steel mold at high pressures that results in faster cycle times and enhanced part integrity of the vehicles. This type of die casting technology helps in the production of complex automotive components with minimal porosity, ensuring the highest quality and durability.

2. Vacuum die casting

In vacuum die casting, the process is carried out in a controlled environment with reduced air pressure. This method minimizes gas porosity in the final product that is being produced, further also improving the structural integrity of the automotive components. In recent times, manufacturers are increasingly adopting to vacuum die casting for manufacturing the critical parts, such as engine components and safety mechanisms.

Innovations in die casting materials

With the aim to create light weight yet robust automotive components, die casting industry has witnessed continuous material innovations. The incorporation of advanced alloys, such as zinc – aluminum alloys, has become prevalent. These alloys not only offer improved strength and durability to the vehicles but also provide a higher degree of corrosion resistance to them. The composition of the materials can also be customised as per the requirements which results in enhancing the overall performance of die – cast automotive parts.

This customization capability not only focuses on specific performance requirements but also opens various opportunities to include die casting materials for diverse applications in manufacturing other different components for automobiles. As a result, the evolution of die casting materials is not just about meeting the current industry needs but also about anticipating and adapting to future technologies and challenges in the automotive manufacturing industry.

Sustainable practices in die casting

In response to growing environmental concerns among the individuals and manufacturers, the automotive industry along with various other industries is also increasingly focusing on sustainable practices for most of the processes. Die casting foundries are also collaborating with many automotive manufacturers to implement eco – friendly measures in their production and all other operations. This includes the use of energy – efficient equipments, recycling of process water and the implementation of green manufacturing practices. This aligns with the automotive industry’s commitment to reducing its carbon footprint.
By aligning the die casting processes with sustainability goals, the automotive industry is moving towards a more environmentally responsible approach that will not only help the environment but will also help the companies in the long run.

Future opportunities

In the ever – evolving industry of die casting, several new and trending opportunities are emerging which is helping to push the industry towards enhanced capabilities and efficiency. Let us have a look at some of the possible future opportunities that lies there for die casting industry with respect to automotive industry.

New materials and alloys

Research into new materials and alloys is opening opportunities for enhanced die casting capabilities. Materials with improved strength and durability are being explored to meet the evolving needs of the automotive industry that will help in the manufacturing of different types of parts and components for automobiles that will be having more stability and resistance to make the final product much better from now.

Smart manufacturing and industry 4.0

The integration of smart technologies and industry 4.0 principles enables real – time monitoring and control of die casting processes. Predictive maintenance, data analytics, estimation of demand – supply and automation contribute to increased efficiency and reduced downtime which helps in the overall growth of the manufacturers as well as of the automotive industry.

3D printing and prototyping

The unification of 3D printing technologies in die casting processes allows for rapid prototyping and the creation of complex geometries that are required in day-to-day basis in automotive industry. This innovation accelerates the product development cycle of the parts and components that are manufactured and supports the customization of automotive components.

Collaborative research and development

Collaboration between die casting manufacturers, automotive companies, and research institutions fosters a scope for continuous improvement. Shared knowledge and expertise can lead to breakthroughs in die casting technology that can also help in analysing the challenges that are faced in the correct manner and take corrective actions and measure to tackle them.

Conclusion

In conclusion, the innovation and efficiency in automotive industry has led to the widespread adoption of die casting techniques, particularly in the manufacturing of light weight and durable components. Die casting not only enhances precision, efficiency, and cost – effectiveness but also contributes to fuel efficiency, automation and flexibility in the production processes that are done for the production of parts and components of automobiles. The diverse applications of die casting in creating complex parts for engines, safety mechanisms and various automotive systems throws light on its pivotal role in shaping the future of the automotive sector with the help of die casting in the process.

The evolution of die casting technology, including high – pressure die casting and vacuum die casting, showcases the industry’s commitment to achieving higher levels of precision during the process of production. Material innovations for die casting are also resulting in contributing to create robust and lightweight automotive components. Moreover, the industry’s increasing focus on sustainable practices focuses on environmental concerns emphasizing a responsible approach towards reducing the carbon footprint.

Looking forward, the automotive industry anticipates exciting opportunities in the near future, including the exploration of new materials and alloys, the integration of smart manufacturing and industry 4.0 principles, the adoption of 3D printing for prototyping and collaborative research and development initiatives. The points mentioned above not only promises improved and enhanced die casting capabilities but also signifies a collective effort towards continuous improvement.

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Aesthetic advantages

Zinc alloys offer numerous aesthetic advantages, including the main one, an excellent tactile feeling which conveys a sensation of robustness and solidity to the object and is also pleasing to the eye due to its technical and technological qualities.

In addition, the design of the zinc alloy components is customizable, both through painting which offers a wide range of colors and finishes to adapt to the desired design, and through numerous galvanic treatments, such as, e.g., nickel or chrome plating, to obtain a shiny and wear-resistant appearance over time.

Functional advantages

The functions of zinc alloys in household appliances, on the other hand, are manifold. The zinc die-casting process offers a unique result in the field of alloys: providing a finished product at the first stage of its processing. That automatically translates into significant savings in terms of costs and production times.

Furthermore, the superior fluidity of zinc alloys allows for thinner thicknesses to be created (unlike other materials, especially plastics), reducing the costs of the raw materials used without renouncing the rigidity requirements of the product, which are fundamental for obtaining equally functional but with a small footprint. In addition, the dimensional stability, resistance to vibrations, and impact resistance are further advantages offered by zinc alloys, making them ideal for internal and external parts of small appliances.

The ductility of zinc alloys is another fundamental aspect of this material and brings great advantages for creating household appliances. This property, in fact, makes it possible to use riveting as an alternative fastening method to screws; reducing the machining costs required for threading and the assembly times needed for tightening the screws; no less important are the aesthetic and cost results for assemblies with rivets, which unlike screws can be hidden from view and translate into economic efficiency since fewer components are needed to create the same finished piece.

Finally, among the functional qualities of zinc alloys, we can also mention the excellent level of shielding from magnetic fields of this material, in fact preventing the electronic and electrical components from interfering with each other, compromising the product’s performance.

Environmental benefits

From an environmental point of view, zinc alloys represent an ecological, eco-sustainable, and ideal choice for a circular economy. Zinc alloy parts are totally recyclable. They can be recovered and reused countless times, helping to reduce the environmental impact of plastic waste and other non-recyclable materials. They require less energy for their transformation, which makes their use more sustainable from an energy point of view.

Economic advantages

The use of zinc alloys, unlike other die-casting alloys, undoubtedly has economic benefits in production. The transformation from solid to liquid state of zinc alloys for die-casting requires lower temperatures and therefore consumes much less energy than, for example, aluminum alloys. That also translates into a considerably longer life of the moulds. With the same use, a zinc die-casting mold can also be used for up to a million cycles without deterioration, allowing for considerable savings in production costs.
This aspect is particularly evident when considering the cost of the moulds for producing aluminum parts, which require more frequent replacements.

Practical examples

A significant example of the application of zinc alloys in small household appliances can be seen above all in the kitchen. Most manufacturers of quality household appliances use zinc or zamak alloy components to give their products solidity, stability, and aesthetic finishes.

For example, the external and internal housings of small appliances are often made of zinc alloy to guarantee a resistant and long-lasting structure. This approach is particularly evident in parts that require greater dimensional stability, such as bearing housings and internal supports of appliances.

Even the supports of electric motors are another example involving the use of zinc alloys. These components, found in many small appliances, can be made of zinc alloy instead of expensive reinforced plastics, offering a more environmentally and cost-effective solution.

Conclusions

Zinc alloys are confirmed as an excellent choice for small household appliances, offering numerous aesthetic, functional, environmental, and cost advantages. Their ability to be machined with precision, resistance to vibration and shock, total recyclability, and process cost savings make them ideal for meeting the needs of modern home appliances. Looking into our kitchens, we can appreciate how zinc alloys are successfully applied in the small household appliances sector. Choosing zinc alloys to produce parts and components means combining attractive design, reliable performance, environmental sustainability, and economic advantages.

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Definition of Zamak components for electromechanical systems

Electromechanical systems are “devices which involve an electrical signal to create mechanical movement, or vice versa mechanical movement to create an electric signal” (source: Electromechanics, Wikipedia). Starting from this premise, although this definition of electromechanics is extremely broad, in this post we preferred to focus on components intended for machine tools which must have properties that allow their best performance in critical environments. We refer to another post the analysis of all those items that, even if inserted in electromechanical equipment, are intended for the building industry and therefore do not have the same technical requirements of strength and robustness that are necessary for components used in industrial environment.

Properties of zinc components for electromechanical systems

Zinc components for electromechanical systems have a number of properties that guarantee their functioning in critical environments with particular stresses. Among these properties we mention:

• Strength, hardness and rigidity
• Excellent surface quality
• Shielding against electromagnetic interference
• Anti-sparkling property
• Fluidity

Let’s now analyze them one by one.

Strength, hardness and rigidity

The choice of Zamak in this industry is determined by the properties of strength, hardness and rigidity that make the material suitable for protecting the electrical and electronic elements of machine tools and production machineries. For example, a Zamak housing for the protection of electrical and electronic components ensures that the elements are not damaged by environmental stresses and impacts.

For an overview on the properties of Zamak and of the different zinc alloys we suggest you to read the article The best zinc alloys for hot chamber die casting.

Excellent surface quality

Another important aspect in the production of Zamak components and in detail of Zamak components for electromechanical systems is the possibility to cast articles with the vacuum valve technology. Casting with the vacuum valve technology allows the caster to obtain components with an excellent surface quality and free from defects, such as the inclusion of air bubbles. This is particularly important in an industry such as electromechanics where it is necessary to protect with specific paints and surface treatments the components from oxidation deriving from the environment in which they operate.

To find out more on superficial treatments of Zamak components we suggest to read the post Coating, plating and other kind of surface treatments.

But how is it possible to cast with the vacuum technology?

This possibility is given by the vacuum valve for zinc die casting. The vacuum valve for zinc die casting is a technology invented in Bruschi in 1983 that has allowed the company to acquire an important competitive advantage over competitors. To discover the history of the invention of vacuum valve we recommend reading the post The history of vacuum valve in zinc die casting.

Shielding against electromagnetic interference

The good shielding properties against electromagnetic interference (EMI) of Zamak are important when it is necessary to protect electronic equipment. For this reason, Zamak is particularly suitable for the construction of housings for motherboards and other kinds of electronic components.

Anti-sparkling property

In addition, Zamak is an anti-sparkling material, this makes it suitable for use in work environments where sparks represent a risk of fire or explosion.

Fluidity

Lastly, the fluidity of Zamak allows the obtainment of components with a high degree of detail and extremely complex shapes directly during the casting process, without the need of secondary mechanical operations. This property of Zamak is therefore particularly useful in the case of components assembled with other types of materials, such as steel and aluminum.

Overview of Zinc products for electromechanical systems

Let’s now analyze some Zamak products for electromechanical systems, explaining their functionality and prominent features. This overview does not aim at being exhaustive because there is an endless variety of solutions that can be realized in Zamak, but it wants to give an idea of the possibilities that can be expressed with zinc alloys.

Protection for switches

In certain environments, such as production plants or aircraft cabins, it is necessary to protect switches in order to prevent them from being activated accidentally. In this case, Zamak proves to be a particularly suitable material because, unlike plastic, it does not risk deforming if subjected to pressure, thus providing ideal protection for the switch.

The product in the photograph, shown here in three color variations, serves precisely to protect a button. All the details are obtained directly during the casting phase, without the need for secondary mechanical processing. However, it is the surface quality that makes Zamak particularly competitive in the production of this component: the surface is smooth, without air inclusions or other surface defects, and is thus perfect for painting.

Housing for switches

The product shown in the photograph is a housing for switches inserted in a control plane. This component has technical, functional and aesthetic requirements: in fact, it has to be made of metal for the strength required in the systems in which it is installed, but it also has a visible part which must therefore be free of surface defects. In this case also, given the customer’s needs, as in the case of the protection for switches, vacuum technology was adopted. The vacuum valve then proves itself fundamental in the creation of the details that allow the housing to be inserted in the control plane. The surface treatment of this product is nickel plating, both an aesthetic and protective treatment.

Limit switch actuators and pressure switches

Both limit switch actuators and pressure switches are components with Zamak elements intended for machine tools and automations. The limit switch actuators, as is evident from the name, are used to produce an output in reaction to the end of the stroke of a component. They therefore have a very wide field of application and can be installed in various types of automation. Pressure switches, on the other hand, measure the pressure of a liquid inside a system, and are therefore installed on instruments that require specific pressures such as some types of brake and machine tools.

In the image in the left there is a limit switch actuator while in the image in the right there is a pressure switch.

For both the component the choice of Zamak as a raw material is determined by specifications similar to those of the products mentioned above. In fact, zinc components for electromechanical systems require strength and resistance in critical environments. Robustness is essential to protect the electronic and mechanical components housed within the product, while resistance in critical environments is achieved through specific surface treatments. In the case of these products, after a first chromation, a powder paint was chosen and the resistance of the components to environmental stress was measured through the salt spray test.

Moreover, as for the products illustrated above, both to obtain the surface quality necessary for an optimal deposition of the paints and for the realization of the small details required by the geometry of the object, the technology used is that of the vacuum valve.

Conclusions

As we have seen, the applications of Zamak components for electromechanics systems are numerous. In fact, electromechanics is an industry that, on various levels, can benefit from the characteristics of Zamak products, both as regards the production of protective housing or enclosures and as regards the creation of functional elements such as end-of-stroke actuators and pressure switches. As previously defined, zinc alloys have characteristics that make them versatile materials: we have seen only a few examples of how they can be used in the electromechanical industry, but the possibilities are many and many more.

Contact us to discover how zinc alloys components can be important elements in the electromechanical industry, click here to fill in the form.

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Properties of Zamak components for the textile industry

 In previous posts in this blog we described the properties of Zamak for the application in different industries, including: lighting, building, electronics, electromechanical, household appliances. As we have already observed, the chemical and physical properties of the raw material and the surface and finishing treatments to which the components can be subjected therefore make Zamak a versatile material, capable of satisfying various types of aesthetic, mechanical or safety requiremensts. For applications on textile machineries also.

The properties required to Zamak components for textile machineries are mainly mechanical: the components must be able to dampen the vibrations of the machinery on which they are installed, to resist the strong wear caused by the sliding of the wires on them and they must have, already during the casting phase as to reduce costs, a precision with very narrow tolerances of the shapes.

In this sector of application also, the fluidity of Zamak is therefore fundamental because it allows to obtain a high degree of detail and complex shapes directly during the casting phase. Moreover, it is also fundamental the excellent surface quality of the Zamak die casts.

Let’s now see in detail these three characteristics of Zamak that are so important for textile machineries components.

Anti-vibration property

 In the textile industry Zamak components are employed in rotor spinning with a single spinning head technology: a technology that can overcome the limits of belt drive and in which the use of antivibration materials is essential. Textile machineries of this kind can in fact have rotor rotation speeds up to 180K revolutions per minute, with an output speed of up to 300K thousand revolutions per minute. This is why it is fundamental to employ HIDAMET (High Damping Metals) raw materials, such as zinc alloys, to make components subjected to this kind of stress. Zinc alloys, in fact, have an excellent damping capacity and this is why they prove to be a perfect choice for this field of application.

To find out more on the anti-vibration properties of zinc alloys we suggest to read the essay of I. Ritchie, Z. Pan e F. Goodwin, Characterization of the damping properties of die-cast zinc-aluminum alloys that can be found here.

Wear resistance

 Wear resistance is a fundamental requirement for components installed inside textile machineries. The sliding of the yarn on the component in fact subjects it to strong stresses which, over time, could damage it by eroding it.

Wear resistance in Zamak components is achieved through different strategies. First of all, the die-casting technology with which the zinc alloys are treated allows to obtain a surface layer, called “foundry skin”, of about 0,2-0,3 mm. The dense fine-grained microstructure of the “foundry skin” gives the zinc components a wear-resistant surface, as reported in the table below.

The tests were conducted on cylindrical specimens of 15 mm in diameter pressed on a hard cast iron disk, dampen with water carrying fine sand with a variable load. After a number of turns corresponding to a path of 10K cm, the thickness of the removed layer is measured. The value, expressed in tenths of a millimeter, provided the relative abrasion data. Zamak alloy, in the conditions in which the tests were carried out, is less consumable than ordinary brass while it is lower only than the 90/10 bronze. (The reported data derive from: L. Andreoni, Quaderno della colata a pressione delle leghe di zinco, Le leghe di zinco, Zama, ed. Edimet, Brescia, 1998).

Another strategy to increase the resistance of Zamak components for textile machineries is to subject them to specific surface treatments. In this case the components are placed on a tray immersed in a chemical bath where, thanks to the rotation given to the tray, they are able to absorb the chemical agent which, depositing itself on the surface, turns into a protective coating.

Possibility to obtain complex shapes and surface quality

The fluidity of Zamak allows to fill even the smallest cavities of the mold obtaining, already during the casting phase, small details and complex shapes. This property proves to be fundamental in an industry, such as the textile industry, in which the tolerances are very narrow and the components, to fulfill their mechanical function, are assembled together.

To deepen your knowledge on these themes we suggest you to read Thin walls thickness: a competitive advantage in zinc die casting.

Surface quality is also an important requirement for components intended for textile machineries. In fact, surface defects such as irregularities, bubbles or burrs could damage the yarn breaking it. Even in an industry such as the textile industry, where the requirements for the components are mainly mechanical, the possibility of obtaining an excellent surface quality directly during the casting phase and of being able to carry out various types of treatments and processes is therefore important.

To find out more on the surface treatments that is possible to carry out on Zamak components we suggest to read Coating, plating and other kind of surface treatments and Processing techniques for metal finishing.

Review of Zamak components for textile machineries

After analyzing the charateristics that make Zamak an excellent raw material for the production of components for the textile sector, let’s now examine some products that allow us to shed further light on the applications of zinc alloy die casting useful in this sector.

Adapter

The adapter is part of the spinning unit of rotating frames. In detail, it is installed on the machines that produce the type of cotton thread called “open end”: a thread intended for thick fabrics such as those of jeans or some shirts and which is opposed to the finer thread that is obtained in two phases, a first phase in which short pieces are made and a second in which the pieces are spliced generating an endless thread.

The component is placed in series on machines with 300/500 units, each independent in the production of cotton thread starting from cotton that is washed and centrifugated in order to make it homogeneous.

All the properties illustrated above are fundamental for this component: the anti-vibration property allows to dampen vibrations and it prevents the thread from slipping, the wear resistance allows the surface not to deteriorate, the fluidity of Zamak allows to obtain, directly during the casting phase, the details that are visible in the image of the post while the surface quality proves to be fundamental for keeping the yarn intact.

Feed Tray Bracket

Feed tray brackets are component derived from the assembly of two articles: feed table and holder.

Both the feed table and the holder have holes inside which magnets are installed, the assembly is therefore possible by magnetic force. The feed tray bracket, differently from the adapter, does not come in direct contact with the yarn and for this reason no particular surface qualities or resistance to wear are required. Zamak, in this case, was chosen for two fundamental reasons: the anti-vibration property and the possibility of obtaining a high degree of detail directly during the production phase.

The anti-vibration property is essential because the component is inserted in a jack rotating at 180K revolutions per minute and, if not able to dampen vibrations, it would risk hitting the other components with which it is in contact causing damage and breakage. The possibility of obtaining a high degree of detail results important for the making of the features of the object, such as, for example, the housing of the magnets that allow the assembly of the article.

Conclusions

In this post we analyzed some Zamak components that can be made for textile machineries, solutions that allow to illustrate the properties of zinc alloys and that result as a winning choice for this kind of mechanical applications.

For more information and updates subscribe to our blog, if you wish to consult our technical office to find out more applications of zinc alloy die cast components for the textile sector fill out the form.

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Characteristics of zamak

Zamak is an alloy composed of zinc, aluminum, magnesium and copper. According to the different percentages of these components the alloy has variable characteristics and can be used for the manufacturing of products for different market sectors. For an in-depth look at different types of zamak and their features, read the article ZAMAK molding in hot chamber die casting: chemical composition.

The characteristics of zamak that are particularly beneficial for the production of components for electronic products are:

Electromagnetic shielding

Zamak has good shielding properties with reference to Electromagnetic Interference (EMI). Therefore, it is especially suitable for the production of housings for electromagnetic cards because it is a product that requires a reduction of interferences

Heat dissipation

The properties of heat dissipation of zamak are similar, if not higher, to those of other materials. In this case, what makes zamak products competitive is the manufacturing cost of the product, the lifespan of the mold and the possibility to achieve products that do not need relevant secondary mechanical operations. For further information about this property of zamak, we suggest this case study: Zinc Heatsink Case Study: Loewe TV Heatsink.

Thin wall thickness and reduced dimensions

Zamak fluidity allows the achievement of a very thin wall thickness and of an extremely high level of detail in components of reduced dimensions. This is particularly important in the case of electronic products, which usually are characterized by very small dimensions and by a great number of details.

Stiffness and anti-vibration properties

These properties of zamak are especially relevant in case of electronic products employed in critical environments. In the industrial field, for example, electronic connections of some kinds of machine tools could be exposed to mechanical stress or vibration. It is evident that in cases like the one just described, zamak offers a protection and a vibration damping capacity that plastic could not offer.

To discover something more about chemical, physical and mechanical characteristics of zamak read the Zinc Association Engineering in Zinc, Today’s Answer, which contains very detailed information on these subjects.

Zamak components for electronic products: characteristics and competitive advantages

Let’s now analyze some zamak components for electronic products to examine their characteristics and competitive advantages.

Hard disk case

In this hard disk case we can observe how zamak properties contribute to the functionality of the product in several ways. Indeed, the case is anti-vibration and this allows the hard disk to work in stable conditions. Furthermore, as you can see in the picture, the product has both very small particulars and thin thickness. Specifically, directly during casting phase thanks to zamak it has been possible to realize the honeycomb grid that allows heat dissipation in the server through air circulation. With other materials the grid could have been achieved only through secondary operations, such as shearing, with unavoidable consequences in terms of timing and costs.

Housing for steering wheel lock

This housing hosts the electronic card of the steering wheel lock. In this case it is the properties of electromagnetic shielding and stiffness of zamak to make the product competitive compared with other similar products manufactured with other materials. As a matter of fact, the shielding allows the electronic card to function in optimal conditions without being subjected to the interference of near electromagnetic fields. Then, for this particular product, stiffness makes zamak especially competitive compared to plastic. Often when plastic housings are installed electronic cards tend to bend, whereas  the stiffness of zamak leads to a higher protection, thus extending its lifespan.

Device for checking, counting and separating banknotes

As far as this product is concerned, zamak has replaced stainless steel, thus cutting production costs and the need for mechanical operations and finishing. This has been made possible by the properties of zamak and especially by the capacity of the alloy to reach thin wall thickness and a high degree of detail. In this way the customer has obtained a product that does not need to be assembled, manufactured with molds with a long lifespan, which need little maintenance and with scrap rates close to zero.

Housing for corporate network connectors

The housing for corporate network connectors is illustrative of the properties of shielding, stiffness and resistance of zamak. For these kinds of products, shielding properties of zamak allow freedom to the electronic designer, who can mitigate the drawbacks linked to the electromagnetic waves without special precautions, but only through the choice of the most suitable material. Stiffness and resistance of the material make the use of the component suitable for particularly critical environments, such as production departments of a plant.

Conclusions

With this brief overview on zamak components for electronic products we have analyzed how some properties of zinc alloys allow the achievement of competitive and effective products. However, these are not the only components for the electronic industry that can be manufactured in zamak. For a more comprehensive overview visit our website www.bruschitech.com in the Services page.

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Caratteristiche della zama

La zama è una lega composta da zinco, alluminio, magnesio e rame. A seconda delle diverse percentuali di questi componenti la lega assume caratteristiche variabili e si presta alla realizzazione di prodotti destinati a diversi settori di mercato. Per un approfondimento sui diversi tipi di zama e sulle loro caratteristiche consigliamo di leggere il post Composizione della ZAMAK per pressofusione.

Le caratteristiche della zama che risultano particolarmente vantaggiose nella realizzazione di componenti per prodotti elettronici sono:

Schermatura elettromagnetica

La zama ha buone proprietà schermanti nei confronti dell’interferenza elettromagnetica (Electromagnetic Interference, EMI). Risulta quindi particolarmente adatta nella realizzazione di housing per schede elettromagnetiche in cui si ha la necessità di ridurre le interferenze

Dissipazione del calore

Le proprietà di dissipazione del calore della zama sono simili se non superiori a quelli di altri materiali. In questo caso, a rendere competitivi i prodotti in zama, sono il costo di realizzazione del prodotto, la durata di vita dello stampo e la possibilità di ottenere prodotti che non necessitano di importanti lavorazioni meccaniche successive. Per approfondire questa proprietà della zama suggeriamo di leggere Zinc Heatsink Case Study: Loewe TV Heatsink

Spessori sottili e dimensioni ridotte

La fluidità della zama consente di ottenere spessori molto sottili e un elevatissimo grado di dettaglio nei particolari di dimensioni ridotte. Questo è particolarmente importante nel caso dei prodotti elettronici dove, a fronte di dimensioni molto contenute, i componenti presentano numerosi dettagli

Rigidità e proprietà antivibranti

Queste proprietà della zama sono particolarmente rilevanti nel caso di prodotti elettronici impiegati in ambienti critici. In ambito industriale, ad esempio, i collegamenti elettronici di alcuni tipi di macchine utensili potrebbero essere sottoposti a sollecitazioni meccaniche o vibrazioni: è evidente come in casi simili la zama offra una protezione e una capacità di smorzamento delle vibrazioni che la plastica non potrebbe offrire

Per scoprire di più sulle caratteristiche chimiche, fisiche e meccaniche della zama rimandiamo alla pubblicazione dell’International Zinc Association Engineering in Zinc, Today’s Answer  che contiene una serie di informazioni molto approfondite su questi temi, ai quali noi abbiamo brevemente fatto accenno.

Componenti in zama per prodotti elettronici: caratteristiche e vantaggi competitivi

Analizziamo ora alcuni componenti in zama destinati a prodotti elettronici per indagarne caratteristiche e vantaggi competitivi.

Case per hard disk

Nei case per hard disk è possibile riscontrare come le proprietà della zama contribuiscano alla funzionalità del prodotto sotto diversi punti di vista. Infatti i case realizzati in zama sono antivibranti e questo consente all’hard disk di lavorare in condizioni stabili. Inoltre, come si può osservare in fotografia, i prodotti presentano sia particolari molto piccoli che spessori sottili. Nel dettaglio, la zama ha consentito, direttamente in fase di stampaggio, la realizzazione del reticolo a nido d’ape che consente la dissipazione del calore nel server tramite la circolazione dell’aria. Con l’impiego di altri materiali il reticolo si sarebbe potuto ottenere solo mediante lavorazioni successive, come ad esempio la tranciatura, con inevitabili conseguenze in termini di tempi e costi.

Housing per bloccasterzo

Questo housing ospita la scheda elettronica del bloccasterzo. In questo caso sono le proprietà di schermatura elettromagnetica e di rigidità della zama a rendere il prodotto competitivo rispetto ad altri analoghi realizzati con altri materiali. La schermatura consente infatti alla scheda elettronica di lavorare in condizioni ottimali senza subire l’interferenza di campi elettromagnetici vicini. La rigidità rende poi, per questo particolare tipo di prodotto, la zama particolarmente competitiva nei confronti della plastica. Spesso infatti, quando sono installate in housing di plastica, le schede elettroniche si flettono mentre la rigidità della zama ne permette una maggiore protezione allungandone la durata di vita.

Apparecchiatura per il controllo, il conteggio e la separazione delle banconote

Nel caso di questo prodotto la zama ha sostituito l’acciaio inossidabile abbattendo i costi di produzione e la necessità di lavorazioni meccaniche e finiture. Tutto ciò è stato reso possibile dalle proprietà della zama e in particolare dalla capacità della lega di raggiungere spessori sottili ed un elevato grado di dettaglio. In questo modo il cliente ha ottenuto un prodotto che non necessita di essere assemblato, realizzato con stampi dall’alta durata di vita e che necessitano di poca manutenzione e con percentuali di scarto vicine allo zero.

Housing per connettori di reti aziendali

L’housing per connettori di reti aziendali è esplicativo delle proprietà di schermatura, rigidità e resistenza della zama. Le proprietà di schermatura della zama consentono, per questo tipo di prodotti, libertà al progettista elettronico che può ovviare agli inconvenienti legati alle onde elettromagnetiche senza particolari accorgimenti ma solo attraverso la scelta del materiale più opportuno. La rigidità e la resistenza del materiale rendono l’impiego del componente adatto ad ambienti particolarmente critici, come ad esempio i reparti produttivi di uno stabilimento.

Conclusioni

Con questa breve panoramica di articoli in zama destinati a prodotti elettronici abbiamo analizzato come alcune proprietà delle leghe di zinco consentano di ottenere componenti competitivi e performanti. Tuttavia, i compoenti per elettronica che è possibile realizzare in zama non si esauriscono qui, per una panoramica più completa potete visitare il sito www.bruschitech.com alla pagina Servizi.

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Zinc die casting for doors and windows

Variety of components made of zinc alloys for doors and windows

Generally, when it comes to zinc components for doors and windows frames one thinks immediately about galvanization, a process in which products realized with various kinds of metal are coated with a zinc layer to increase their superficial resistance.

However, it is possible to create a large number of components for doors and windows entirely made of zinc alloy.

Among these zinc alloy products some of them are more traditional and characterized by a long productive tradition in Zamak, such as corner transmission, case, external casing for panic exit handles, while some of them are more modern and linked with the recent developments of home automation, such as the keypad case for the remote opening of doors and windows or the covering plate for hotel door locks.

In this article, after briefly depicting the advantages that make zinc alloys a winning choice for the building industry, we will examine more in depth the productive process of some components for doors and windows. These products will be reviewed analyzing their productive process, their capability to undergo superficial or finishing treatments and the possibility of optimization in terms of design.

Competitive advantages of Zamak

Producing the previously mentioned components in zinc alloys results in a great advantage both for the final consumer and for the producer of windows and doors.

The use of zinc as raw material and the hot chamber die casting process allow the reduction of finishing operations and make it possible for the product to undergo a number of protective or aesthetical superficial treatments and for the production time to be reduced.

Differently from other materials, such as aluminum for example, that need different processing in different phases, Zamak allows the die caster to obtain, with a process that can be almost entirely automated, components ready for assembly. Moreover, thanks to the physical-chemical properties of Zamak, it is possible to reach final shapes with centesimal tolerances and to avoid the expensive mechanical operations that are required for the finishing of other metals.

Finally, a last competitive advantage of zinc alloys compared to other materials is the possibility to reach a minimum thickness of about 0.3 mm that, together with the capability to obtain complex geometrical shapes, allows a great design freedom.

To deepen your knowledge on superficial treatments for building industry components read the article Zinc Die Casting Finishes for Building Sector.

Requirements for zinc components for doors and windows frames

Zinc components for doors and windows frames can be characterized by a prevailing technical or aesthetical purpose but often it is necessary to comply with both these requirements. The products employed in this industry, indeed, are exposed not only to the final user sight but, in the majority of cases, also to external atmospheric agents. For this reason it is necessary to guarantee a superficial resistance able to remain unchanged over time. Indeed there are few pieces that stay hidden in the internal part of the frame and often also these components become visible when the frame is opened: therefore aesthetical quality is one of the main requirements for this industry.

However, we must not forget that components that at first sight seem to perform an exclusively aesthetical function, such as, for example, the cover plates of some locks or the external casing of handles, actually hold functional mechanisms and, with technological advancement, they have to comply with increasingly strict technical requirements

Let’s look at these components in detail, taking into consideration their productive process and the possibilities and the advantages that they offer in terms of design, and economic saving.

Components for traditional doors and windows frames

As previously mentioned some components in zinc alloys for doors and windows have a long die casting tradition. Already since the middle of the last century the technical advantages connected to the material and to the technologies of its processing did not go unnoticed. Below some brief case studies that depict the manufacturing process of these components.

Corner transmission

The corner transmission is a purely functional component: it is the mechanism that transmits the motion received by the rotation of the handle for the vasistas opening of frames. As already defined, the component becomes visible when the user opens the window and thus, even if it is often hidden, it is necessary for it to have a pleasing aesthetical appearance for the final user.

For this reason designers have to  design a product with functional characteristics and, in parallel, also an aesthetical value.

Thanks to versatility and to the characteristics of zinc it is possible to find, already at a design level, technical solutions for both the objectives. Even in the case of a functional component with an aesthetical quality, such as the corner transmission, die casting allows the achievement of a finished object with minimum thickness, narrow tolerances and aesthetic value such as to satisfy the final user.

Case

The case is a component of the opening and closing mechanisms of doors and windows. The piece has a technical function because it holds together and covers the linkage mechanism of transmission of the rotary motion in linear but, in addition to this function, as in the previous case, the case is distinguished by a noticeable aesthetic value because it is directly inserted in the living environment. Precisely for this aesthetic value the case undergoes superficial treatments aimed at increasing the superficial quality: this component, depending on the customer needs, can be coated or chromed.

Choosing Zamak for the production of the case is eventually profitable not only from a technical and aesthetical point of view, as already observed, but also from an economic perspective. In fact, zinc alloys allow the die caster to diminish the number of secondary operations because, thanks to their fluidity characteristics, they allow the realization of complex shapes. Thereby, thanks to Zamak, it is possible to obtain a number of details and micro details already during casting phase, without having to perform mechanical operations in other phases of the productive process.

For a further analysis of the characteristics of zinc we suggest you to visit the page from the International Zinc Association website.

Moreover, still concerning saving, the possibility of processes automation given by its technical characteristics makes Zamak competitive in comparison to other metals. In the specific case of the realization of this component it has been possible to automate the casting process up to the complete threading of the object without the contribution of personnel and therefore with a consistent saving on the cost of direct operators.

Case for panic exit handles

The case for panic exit handles is the housing of the mechanism that is connected to the central handle that allows the opening of the door. Every panic exit handle has two lateral cases that cover the opening mechanisms and they perform both a technical and aesthetical function.

Relatively to the aesthetical function, the use of zinc alloys makes it possible to perform a great variety of finishing aimed at obtaining functional or aesthetical objectives, such as, for example, the treatments to protect the component from weathering. This allows a great freedom of choice for product designers: in this way they can follow functional criterions without renouncing aesthetical factors.

Also relatively to technical aspects, the choice of zinc alloys provides actual advantages to the productive process. The possibility of producing components with thin walls thickness allows the die caster to create components employing less raw material in comparison to other metals, with a self-evident advantage in terms of costs for raw material and for energy necessary for the change of state.

In the specific case of the external case for panic exit handles various analysis, conducted with specific simulation software, made it possible to obtain an optimized product with a noticeable reduction of wall thickness starting from the previous design provided by the customer.

Zinc alloys for automated windows and doors

As defined, if for some zinc components for doors and windows frames die casting is a technology that has been used for a long time, for some others components, which are more innovative and modern, this kind of production is substantially a new field. Home automation and associated technologies are growing steadily and so is the smart locks market. If it is true that doors will still have hinges, locks and handles it is also true that it is necessary to reconsider these components to make them able to support automation and electronics. However, new functionalities require the design of new solutions: in fact, for example, the presence of circuits and electronic commands necessary implies an activity of redesign and redefinition of the components. Thanks to their fluidity and their chemical-physical characteristics Zinc alloys, manufactured with the die casting process, allow the creation of complex shapes and thin walls resulting therefore particularly suitable for the production of components for home automation. In particular, two components that can be produced with zinc alloys appear with an increasing frequency on the market, so much that they have become common used. These components are the keypad case for remote opening of windows and doors and the cover plate for electronic locks.

Plate for electronic locks

The first of these zinc alloys for windows and doors components is the covering plate of electronic locks. The plate, considering its covering function, has to primary meet aesthetical requirements. However, in parallel, it also has an housing function for the electronic components that allow the opening of the locks: for this reason, as in other previously mentioned cases, besides the aesthetical value also technical aspects have to be considered.

The die cast, after the casting process, is separated from the injection channel, then it is thermal deburred and threaded. Afterwards it is prepared for the superficial treatment with polishing process and it is galvanized to obtain the finishing of satin or polished chroming and gliding. These treatments increase not only the aesthetic value of the product but also its superficial resistance and, as a consequence, its lifetime. Zinc alloys, also in this case, allow the producer to obtain, through optimized and automated processes, products with an excellent superficial quality at competitive prices in comparison to those for the same product realized with other metals.

Keypad case for the remote opening of windows and doors

A second zinc component for doors and windows frames that is increasingly common is the keypad that allows the opening of doors and gates by code. Also in this case the requirements are both technical and aesthetical: the piece, exposed to the weather conditions, has to resists salt spray tests, to keep an excellent aesthetical quality over time and to host, protecting them, the internal electronic components. Zinc, characterized by dimensional stability and resistance to the different weather and climatic conditions, proves to be an optimal choice. Finally, the capability to take complex shapes and to achieve an high level of detail and precision allows the customer to design the component with freedom in such a way that he or she can obtain the most satisfying product.

Conclusion

The employment of zinc alloys through hot chamber die casting process, in comparison to other alloys or technologies, often results in an economic advantage for the producer of components for doors and windows frames. In fact Zamak allows the reduction of secondary operations and the automation of a consistent part of the processes: with a great saving in terms of time and costs. Moreover, the design freedom, the possibilities offered by optimization and the great variety of superficial treatments that it is possible to perform on zinc components for windows and doors frames allow the achievement, without waste of time and material, of products that are compliant with the requirements defined by the customer and that are ready for the final user.

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Competitive advantages of lamps and lights in zinc alloys

The lighting market demands specific requirements that Zamak components are perfectly able to meet. Let’s explore some of them:

Employment of zinc alloys with led spotlights and CFLs

In 2005, with 2005/32/EC directive, European Union introduced the gradual substitution of incandescent bulbs and halogen spotlights with products with lower energy impact: such as led spotlights and compact fluorescent lamps (CFLs).

This directive completely changed the situation of the lighting market, allowing producers and designers to adopt new technologies and to expand the range of possibilities: both in the choice of materials and in the design of the products.

One of the consequences of the employment of these new lighting technologies is that zinc alloys have become competitive in comparison to other metals.

In fact, in the past high temperatures reached by lighting systems imposed the realization of articulated heat dispersion systems, which actually limited the employment of Zamak. Now, with the new regulations, it has become possible to employ Zamak for the creation of lamps and lights with innovative shapes and qualities.

Sustainability of the productive process

CFLs and led spotlights allow a saving on the cost of electricity bill because to produce light they employ less energy than other technologies: this means more saving for the final user and more environmental sustainability globally.

Also Zamak, even if in a different way, allows an important energy saving: thus proving to be a winning choice. Melting and manufacturing zinc alloys in fact requires less energy than that required for the treatment of other metals or metal alloys.

In addition, always on the subject of sustainability, at the end of their life cycle zinc products are 100% recyclable.

The productive process of zinc alloys components is less energy consuming compared to others and, together with the lesser energetic expenditure of the lighting system and the recyclability of the products, allows the producer that choses to use these products to make really informed choices. The advantages deriving from the choice of Zamak for components of lamps and lights do not affect only the producer of lighting components but also the final consumer and the environment. The producer will save on the creation of the components, the final consumer will have more choice and saving opportunities, and all of this while respecting the planet and its resources.

Life span of molds

The melting temperature of Zamak, lower than the one of other metals or metal alloys, means a further advantage for the producer of lighting components. In fact with a lower melting temperature of the metal also the wear and corrosion of the mold will be lower.

This means an important advantage in terms of life span of the mold and of decrease in the number of maintenance and repair works necessary to mass production.

Thanks to the choice of Zamak and to the hot chamber die casting process, with which the metal alloys are manufactured, the producer of lighting components will be able to produce large volumes of products over long periods of time in view of an initial investment for the mold that will not incur additional expenses in the medium and long term.

Possibility to create complex shapes with an high degree of detail

Lamps, lights and spotlights are design objects and their shapes are often articulate and complex. Zinc alloys, thanks to their fluidity, allow the creation of the shape desired by the customer directly during the die casting process without the necessity of further mechanical operations.

Over the possibility to create every kind of shape, the fluidity of zinc alloys makes it possible to obtain, already during the die casting process, all those elements that are necessary to the functionality of the product such as treads, holes, plugs and wings for the potential heat dispersion.

Moreover, zinc alloys allow the creation of components with extremely thin walls: this way the employment of raw material is reduced. In the case of lighting products the advantage is not only economic but also functional: lamps and lights with finest shapes can be hang more easily and can be better integrated into the furnishing environment.

Aesthetical factor: superficial treatments

Lastly, also regarding superficial treatments Zamak die casts prove themselves to be competitive compared to products made with other kinds of metals.

Zinc alloy die casts allow low cost mass processing, for example vibration and thermal deburring, with a noticeable advantage regarding also delivery times. In addition, the surface of zinc alloy die casts is ideal for receiving different kinds of treatments such as chroming, gilding, liquid or powder painting. This way products can take on the exterior appearance required by the customer.

In an industry like the lighting one this characteristic of great adaptability is very important because it allows the products to integrate harmoniously with different styles and furnishing environments, allowing a wider catalog and helping designers to wholly express their creativity.

Lighting components: case studies

After analyzing some of the reasons why Zamak components are competitive and particularly indicated for the lighting industry we will now examine some products underlining their characteristics and peculiarities.

Body for recessed spotlights

This component, with simple and elegant lines, hosts and frames the spotlight that is to be recessed into the wall. The frame of the spotlight can be round or squared but it can also assume more complex shapes in order to satisfy the design needs of the producer. Furthermore, the variety of superficial treatments, chroming, gliding, liquid or powder painting, as previously mentioned, allows great versatility to the product that can be inserted in different kinds of furnishing environment.

Table lamp: led support

In this case the customer desired a polished product, able to reflect light, characterized by simple and clean lines. Zamak made it possible to obtain, with an extremely limited number of processing, components with the thin walls required by the design of the object and with the smooth and defect-free surface perfect for chroming.

Adjustable spotlight for shops

This adjustable spotlight is intended for the lighting of shop windows: where it is necessary to direct light in specific directions. The product consists in two components: the mobile case and the external frame. The frame is the support for the case that, as anticipated, can be regulated to direct the light beam.

For the product in the photography the painting chosen by the customer is a white painting, in this way, in fact, the frame merges with the wall of the shop window without visually interfering with the exposition of the products it lights up.

Ring for cable spotlights

Cable spotlights are ideal for all the environments in which it is necessary to illuminate a room in all its length. The lighting system in fact allows the installation on parallel tracks of the desired number of spotlights and makes it possible to orientate them accordingly to the needs.

This ring for cable spotlight is a product designed for a minimalistic and elegant lighting. Its surface is chromed and it appears smooth, polished, bright and without any slightest defect.

Furthermore, the product is representative of the capability of Zamak to reach extremely thin wall thickness. In fact the die cast has been obtained, directly during casting phase, with all the elements that assure its closure and functionality. In addition, the reduction of wall thickness, with the weight diminution that it implies, results optimal for a cable lighting system.

Case for cable spotlights

This product is a design item with a particular shape that integrates a heat dispersion system. Also in this case it has been the productive freedom allowed by Zamak to allow the realization of all the details required by the customer in a single component.

In the picture it can be noticed how the surface of zinc alloys die casts allows an optimal result of gliding: also this products stands out for its brightness and for the quality of its surface.

Conclusions

Lighting components made of zinc alloys, whether they are lamps, lights or spotlights, are therefore products able to stand out and to be advantageous from many points of view. From the point of view of creativity and design they allow great design freedom making it possible to create, with a mass production process, products with unique and particular shapes.

Furthermore, Zamak die casts, thanks to the great number of superficial treatments they can undergo, are particularly indicated as components for furnishing products because they are able to integrate with different styles and environments.

Finally, economic and environmental advantages are not to be underestimate: to choose Zamak as raw material and die casting as productive process allows energetic saving and the employment of recyclable and sustainable materials.

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