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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The advantages of zinc die-casting

Before we delve into the importance of design, it is essential to understand the benefits of zinc die-casting. This manufacturing process allows for components with complex geometries, small, high-precision details, and thin walls, offering a wide range of design possibilities. Using zamak as a casting material offers, among various positive properties, good mechanical strength, effective resistance to corrosion, and excellent thermal and electrical conductivity. The above advantages facilitate the designer’s work in the search for the most suitable material and production system for the product in the design phase, offering various construction possibilities provided by a single alloy.

The excellence of design

Design is undoubtedly a crucial factor in the success of any product, and in zinc die casting, it is no different. Functional design is all about balancing form and function, combining aesthetics and practicality to create a product that is attractive, functional, and efficiently buildable. In the case of zamak die-casting, the shapes of the product must be designed considering the possibility of being obtained from a mold and the ease of filling the mold with liquid metal. This aspect represents a fundamental factor for an efficient production process, as we have analyzed in the post: Surface defects in zinc die casting: flow marks, blistering and sink

Engineers and designers must also consider several crucial aspects to achieve design excellence.

Features

The functionality of a product is the fundamental element. It is essential to understand the component’s technical specifications and ensure that the design meets these requirements. Just as it is important to verify that the die-casting production process allows the creation of the shapes identified in the design phase, this involves careful assessment of mechanical stresses, tolerances, thermal and electrical properties, and interactions with other components in the system.

Aesthetics

In addition to functionality, aesthetics play a significant role in zinc alloy die-cast products. Well-designed products must be aesthetically pleasing and reflect the manufacturer’s identity. The design must take into account proportions, surfaces, finishes, and other aesthetic elements to ensure an attractive appearance. In fact, zinc alloys accept the application of a great variety of finishes, from various galvanic treatments to any type of coatings. The designer, therefore, has a vast range of solutions at his disposal to define the aspect of the product that is most suitable for the target market.

Feasibility

Zinc die casting offers a high level of flexibility in producing complex components; however, it is essential to consider production feasibility from the beginning of the design process. Designers must understand the capabilities and limitations of the zinc die-casting process and design the component to maximize manufacturing efficiency. For this purpose, close collaboration between designers and die casters is essential; the initial co-design activity is, in fact, one of the most critical elements for achieving the product’s productive and commercial success.

Choice of materials

Choosing the right material is crucial to successfully designing zinc alloy products. Zinc offers a unique combination of properties that can enhance product performance and life. Selecting specific zinc alloys for die casting and optimizing them for the needs of the product can significantly influence its success.

Conclusions

Achieving design excellence in zinc die casting requires carefully balancing design and function. A well-thought-out design not only fulfills the product’s functional requirements but also offers attractive aesthetics and efficient production. Investing time and energy in the design of zinc die-cast components can lead to outstanding results in terms of reliability and commercial success. With the proper attention to detail and collaboration with industry experts, it is possible to produce zinc die-cast components that meet both quality standards and aesthetic expectations.

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How to prevent cavitation?

In the molding of articles by means of zamak die casting, considerable difficulties can arise in achieving the surface quality of the casting to meet the customer’s aesthetic requirements.
In order to achieve a good surface quality of the die casting, i.e., without marbling, it is necessary for the liquid metal to reach all areas of the impression as quickly as possible and without yielding temperature. Hence the need for high pressures and high flow velocities in the filling phase.
High pressures give rise to the phenomenon called “water hammer” at the end of the filling phase, while high velocities generate flow turbulence, both of which are crucial factors in the occurrence of cavitation.
We have found in our experience that using liquid zamak injection speeds below 60 m/s significantly reduces the occurrence of the phenomenon in the mold surface – an important fact to consider when designing the mold and the process.

The use of simulation programmes to fight cavitation

A very useful tool used daily in Bruschi’s engineering area is simulation software.
With these programmes, the engineering team can simulate the filling of the product in order to design casting and vent channels capable of achieving the quality required by our customers without, however, causing premature deterioration of the mold.
During the realisation of projects, from the design phase to the production phase, with the simulation software it is possible to prevent all possible defects on the mold. In this way, Bruschi can to save time by predicting possible problems, achieving customer goals in the best possible way.
These simulations are of such importance that they are also taken into great consideration during the bidding phase to the customer, as they prove essential in anticipating any eventuality.

Conclusion

The aim of engineering is to solve the cavitation problem by studying the behavior of the fluid inside the molds on a daily basis. These evaluations are carried out using simulation software, with which Bruschi can visualise parameters such as flow velocity, pressure inside the mould and filling temperature of customer products.
Considering that each product has a unique geometry, different issues and new daily challenges arise and are addressed to ensure quality products for the Bruschi team and its customers.

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On the subject of mechanical strength, and more in detail, breaking load, in this post, we will briefly define the function of rupture tests in the structural quality control of zinc die castings during production. This article will also describe the instrument used to perform these tests to ensure compliance with the specifications of the component and some case studies related to the main topic.

Ultimate tensile stress: breaking strength test of a part or assembly

As anticipated, the ultimate tensile stress is the force that must be applied to a component to cause yielding and/or rupture and is measured in mega-pascals, indicated by the symbol MPa, which is the primary unit of pressure measurement, that is, of the force on the unit of surface.

In order to proceed with this test, the force is applied at a point of the piece predetermined and agreed with the customer to observe the load necessary to cause its breakage or yielding. In this way, it is possible to test the amount of force needed for the test piece to lose the specific mechanical properties, that is, the ability of the component to withstand external loads and, consequently, be unusable.

The execution of this process requires a specific machine for laboratory tensile/compression tests.

Therefore, this machine is extremely crucial because breaking strength tests are among the key elements for the functional verification of a finished product. Often individual zinc die-cast components are mounted in an environment or in an assembly that undergoes various stresses from the outside, and these forces, if not adequately considered and analyzed, could compromise one or more elements of the system by jeopardizing the function of the product itself. An obvious example of this concept is undoubtedly the steering group of a car that undergoes different stresses due to different drivers. The individual elements and the system must necessarily be able to perform their function without breaking even in the event of excessive forces applied by drivers with extreme driving styles. Consequently, avoiding malfunctions and ensuring the correct mechanical strength of steering components is an essential safety factor for the driver.

The ultimate tensile stress: real tests and computer simulations (FEM)

This kind of test can also be simulated within CAD (FEM) applications, but as the die casting process is known, also using vacuum technology, it does not allow the molding of parts with theoretical material density because, as a result of the volumetric shrinkage during the cooling inside the zones of the die-cast with a higher mass, microcavities are created, typically called shrinkage porosity, which could compromise the performance of the product in terms of mechanical strength. These density variations are not completely intercepted by the simulation software systems, which can be very useful in the design phase but which, in terms of production, could call into question the achievement of the required specifications due to the inaccurate results detected by the simulation program. For this reason, it is recommended to use simulation programs to define an idea of reality, a production guideline, and then, directly in the foundry, instead proceed with sample checks during the molding and verify in detail every single aspect related to mechanical strength.

Having constant real-time control over the production, cyclically checking on a sample basis, is therefore essential to verify if the production complies with the customer’s specifications. Thus, the advantage of using these control instruments directly in production involves continuous control and the ability to act in real-time to avoid any line interruptions.

In conclusion

As we have briefly observed before, the tests in production of the ultimate tensile stress do not replace the simulations, but they place side by side with different objectives. These are critical, periodic tests to ensure a reliable and specific process during production.

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In this blog post, the goal is to imagine the future trends and scenarios of this process, since modern die casting has embarked on a decisive path of evolution compared to a few decades ago.
Speaking of the zinc die-casting of tomorrow, one cannot ignore the opportunities offered by simulation software.

Numerical simulation in zinc die casting

The numerical simulation of all processes allows adding value to the die casting activity because it allows reducing the time to market, optimizing the testing and verification phase and thus obtaining significant cost savings.

Numerical simulations are normally already considered for the entire filling process (see blog post: “Simulation for HPDC: scrap reduction case study“), but their use could be extended more and more to the general study of the behaviour of the die-cast object during the withdrawal phase or in the detection of any internal tensions, up to analyzing any possible anomaly in its structure and surface.

In this way, the approach to die casting becomes much more structured, moving from empirical criteria (or “trial learn”) to data-driven methodologies, capable of allowing cost and resource savings and making more informed decisions.

Furthermore, process and product simulations can serve as a database to lead zinc die casting to the discovery of new application sectors. In Bruschi, for example, simulations on thin thicknesses have given useful results for different fields of use and also in the automotive field, thanks to the simulation activity, new zinc components have been created, which perhaps without this type of analysis would not be never born.

The impact of technology on new die casting processes

Even at the process level, zinc die casting has important innovations in store, especially in Bruschi, and all are related to the contribution of technology to operational needs.

To overcome the cavitation problem, for example, certain analyzes are currently being carried out to minimize its impact, but the use of fluid-dynamics simulations is currently being studied, again through software, in order to be able to modify the feeding channel and the flow system at the origin to prevent this phenomenon from damaging the mould.

With reference to the new die-casting techniques, on the other hand, the attempt to apply the hot runner injection process, typically used in plastic moulding, to the zinc alloy is under consideration. This technique would make it possible to avoid the generation of the so-called “sprue”, reducing the costs in the management of the process connected to its subsequent elimination. The amount of heat saved by the absence of sprue to eliminate would also bring with it important consequences from a green perspective such as the production of less CO2 and therefore greater respect for the environment.

Also as regards the machines, technological progress allows to have more and more sophisticated systems for the control of the main parameters of the die-casting process, also giving the possibility to deepen the correlations between those in input (speed, pressures and characteristics of the injection profile ) with the outgoing ones (weight, burrs, surface quality), through the aid of statistical process analysis software.

Finally, we point out the studies conducted for the production of new sustainable zinc alloys, which are made exclusively through the treatment and recycling of new zamak scrap deriving from the die-casting process. This type of product allows you to embrace the themes of the circular economy, zero waste and recycling which, until a few decades ago, seemed utopia, when compared to the world of foundries. For further information on this topic, we recommend that you contact Bruschi by filling out the form at the link: https://www.bruschitech.com/contact-us-bruschi.

The advantages of zinc die casting

The advantages of zinc die casting, compared to the use of other materials such as aluminium, are numerous.

The first advantage is the greater ease of management of the final surface treatment (chrome plating, painting…). This plus linked to the use of zinc is very useful for all those applications that must meet both aesthetic and functional requirements (for example, resistance to corrosion) and is increasingly in demand on the market.

In addition, zinc die casting has a lower process cost because the zinc alloy mould lasts up to five times that of aluminium, which deteriorates much more quickly as a result of the higher melting temperature (650°C than aluminium against about 400°C of the zamak).

Then, the cycle time of the process is much faster because zinc can be treated in a hot chamber, while aluminium can only be treated in a cold chamber. We refer to the blog post “Zinc Die Casting: A Look into the Future” for the technical explanation of the difference between the two processes. What should be emphasized here is that the hot chamber process, which has always been used in Bruschi for the production of zinc alloy components, allows for greater speed in the production process and an important reduction in mechanical processing subsequent to the die-casting phase.

In conclusion: the future of the zinc die casting market

Despite the current economic situation, the die casting market is showing some encouraging trends. From today to 2026, estimates speak of a global increase of 6%, to which the zamak market also seems to comply.

Surely the technological progress that zinc die casting is undergoing and that passes, as we have said, to the ever-increasing use of software and simulation technology, can help to shift the interest of those potential customers who usually turn to the plastic or aluminium market to the zamak market.

Everything lies in continuous innovation, which can lead to the creation of high-quality zinc alloy die-cast objects from an aesthetic and functional point of view and with an important saving from the point of view of production costs. Bruschi has the ambitious goal of being at the forefront of the die-casting market and is continuously receptive to new techniques and methodologies to be applied to everyday operations to help improve the sector.

The post What is zinc die casting? What will it be like in 2022? appeared first on Bruschi.

Industrialization of the product in zinc die casting

Industrializing a product means facing the entire design process taking into account the functional, qualitative and aesthetic specifications of the customer and of the construction technology, which in this case is the hot camber die casting of zinc alloys.

The industrialization of the product is therefore a complex process composed of various phases in which various departments intervene. Let’s analyze the delicate process that leads to mass production.

DFM

Already in the RFQ (Request For Quotation) phase, therefore still in the commercial phase, the project proposed by the customer is evaluated and analyzed in order to present an offer. Afterwards, once the sales process has been completed and the order from the customer has been received, the most substantial and vertical activities are undertaken. One of these activities is, for example, co-design: a phase in which the technical departments of the customer and of the supplier work together to optimize the product.

The study undertaken on the product, the co-design activity mentioned above, makes it possible to propose a series of activities aimed at increasing value and reducing costs, both as regards the product and the production process. The work carried out at co-design level culminates with the drafting of Design for Manufacturing, called in technical jargon DFM, a document that defines the most suitable shapes for the production process of the die cast and the tools that are necessary in the different phases of the process: mold, automations, frame for superficial treatments and others.

For a definition of DFM approved by the scientific community and for additional related information we recommend visiting the Society of Manufacturing Engineers website.

It is important to underline how the modifications suggested in this phase not only concern the aesthetic aspect or the functionality of the product, but also the resolution of problems emerged during the study phase: whether they are at product level, such as critical areas and deformation or too narrow tolerances, or at process level, for example it could be necessary to find alternative solutions for the configuration of the mold extractors.

For further information on DFM we suggest you to read the article Product design for die casting: how to speed up and optimize your DFM.

Kick-off

Once this initial phase has ended, it is time to bring together for a second time all the actors involved in the process with a meeting called kick off. The kick-off is the moment of the launch, typically it is a meeting called by the Project Manager in which all the departments involved in the realization of the project come together to discuss the production aspects. During the meeting, conducted by the Project Manager, the following areas intervene:

• Design: designers highlight the critical aspects of the product and the solutions identified at design level
• Quality: on the basis of the observations of the designers it identifies the elements on which it will have to focus its attention and the kind of analysis that it will be necessary to undertake to guarantee the respect of the requirements of the customer
• Production: it evaluates the technical aspects of the productive process and the relative criticalities, establishing machines, automations and processes necessary for the realization of the product
• Logistic: it manages the warehouse and its critical issues and the shipping of the goods to the customer
• Sales and marketing department: oversee communication with the customer at every stage of the project life, providing feedback on the progress of the processes

Kick-off is a very important moment because at the end of the meeting all the departments are ready to act together for the success of the project. At the end of the kick-off is therefore possible to start the construction of the tools necessary for production.

Sampling

During sampling phase the first samples, defined first off tool, are created. It is in this phase that the die casting mold and all the tools that will be necessary during mass production phase are tested.

All production departments contribute to the evaluation of the samples that are subsequently sent to the customer in order to obtain the approval.

Samples allow the verification of the compliance of the product to the requirements of the customer and the necessary analysis are undertaken by quality department and afterwards by the customer.

Samples, beside die casting process, can undergo different kinds of treatments. In some cases raw parts are sent to the customer, in other cases mechanical operations or superficial treatments are necessary.

In the case of superficially processed samples, external suppliers are involved. In this case it becomes necessary to carry out checks on the products arriving from suppliers and consequently on those delivered to the customer. In fact, it is important to monitor quality throughout the entire supply chain so as to guarantee to the customer products that are always compliant and that have passed strict controls.

Pre-Series

If sampling is aimed at the analysis of the quality and the dimensions of the samples the pre-series allows the verification, on a reduced scale, of the compliance to the established standards for the productive process.

In pre-series phase in fact the products are created with all the techniques and the processes that will be undertaken in phase of mass production allowing the verification of cycle time, of the production capacity of the plant and the respect of the parameters set in design phase.

Since the runs of the pre-series are limited and sometimes the product or the mold have to be subjected to modifications, in zinc alloys die casting it is advisable to carry out the pre-series, and the previous sampling, with prototypal molds. The prototypal molds do not have the lifespan of the molds for mass production but they are more suitable for the execution of modifications.

Importance of collaboration

We have seen how in the industrialization of the product expertise from different departments intervene at different levels and in different phases of the process. The operative bonds between the different departments become particularly evident in this phase and they are decisive in the functions of coordination, timing, management of the resources and project management.

Moreover, in industrialization phase the collaboration goes beyond the boundaries of the company and it involves customers and suppliers. In fact, the process of co-design can be undertaken only together with the customer and it is thanks to collaboration with the latter that it is possible to establish strategies aimed at reducing costs and at optimizing the product.

Also the collaboration with suppliers becomes fundamental because only through a careful monitoring of the entire production chain  it becomes possible to guarantee the quality of the products and to obtain the approval of the customer.

Conclusions

In this brief article we have described the phases that precede mass production of a component, then focusing on collaboration that is necessary for the success of any project, in particular in a delicate phase as the industrialization of a product.

In conclusion, we believe it is important to underline how, in this process, the Project Manager is a key figure that has to constantly monitor the processes and the contribution of every department verifying that, step by step, all the necessary operations are performed. It is only through the right collaboration that, in an articulate process composed by a number of steps, it becomes possible to achieve the goal in the best and efficient way.

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Cost reduction strategies in zinc die casting

Cost reduction in zinc die casting can be implemented in different ways. In fact, zinc is a versatile metal that, if manufactured with the right technologies, allows saving not only in absolute terms, because it allows the die caster to save the time, energy and raw material that are required in the process, but also compared to other metals.

In the production of die-casts it is possible to implement cost reduction by:

•  Choosing zinc instead of other metals or other metal alloys
•  Optimizing the productive process
• Designing processes and components together with the customer through co-design methods

  When it comes to save during die casting process it is also important to choose the right die caster, if you want to learn more on the matter read How companies can save while selecting the die caster.

Advantages of zinc: chemical and physical qualities and characteristics, melting temperature, circular economy

Zinc alloys usually employed in the die casting process have some properties that make them competitive if compared to other metals. These are chemical-physical properties that allow the reduction of costs related to productive processes and to the subsequent stages, such as, for example, those of disposal and recycling. Let’s analyze these characteristics in detail.

Chemical-physical qualities and properties

In the die casting process different zinc alloys are employed. The most common of those alloys are Alloy 2, 3 and 5, and they are chosen for the production of different components depending on their chemical-physical properties. In fact, according to the percentage and the relative values of the metals that are contained in them, the alloys have different characteristics that make them more or less appropriate to realize different typologies of products. For example, if the component is a safety product the alloy that guarantees the greatest resistance to wear, corrosion and pressure, yield strength and dimensional accuracy is to be chosen. In case of a technical component, for which it is often important to achieve details and thin ribs, the Zamak to be preferred will be the most fluid because it will be capable of spilling over the mold in the most uniform way. In this way it will be possible to obtain thin walls thickness that is essential to guarantee the functionality of products. Finally, for aesthetical products Zamak alloys able to ensure the best surface quality and the best performance if subject to subsequent processing and finishing, are to be preferred. Therefore it is very important to know the chemical-physical characteristics of the different zinc alloys in order to choose the most suitable for the production of a specific component. Only in this way, in fact, it is possible to make a winning choice and obtain, with reduced scrap rates, quality die casts that need a reduced number of finishing and further processing.

If you want to discover more about different zinc alloys and how to take advantage of their specific characteristics read the articles The best zinc alloys for hot chamber die casting and Zamak molding in hot chamber die casting: chemical composition.
To deepen your knowledge about the advantages of zinc in comparison to other metals read The importance of zinc die casting in automotive industry and Coating, plating and other kind of surface treatments.

Melting temperature

One chemical-physical property that has a great impact in terms of cost reduction is the melting temperature of Zamak. The melting point of Zamak, in fact, is low and this allows hot chamber die casting. Differently from aluminum, which has a higher melting point and that is cold chamber die cast, Zamak allows energy saving provided by the different technological process used to melt the material. There are further advantages related to time that are connected to hot chamber die casting: hot chamber die casting is a faster process than cold chamber die casting and, as a consequence, it has an increased productivity. Another saving factor related to melting temperature is that the mold, subjected to lower temperatures, is affected by less wear and, for this reason, has a longer lifetime, with beneficial effects especially in large scale production.

Circular economy

In this brief review of the qualities of zinc in comparison to other metals one last property has to be mentioned: recyclability. Zinc, in fact, fits in circular economy processes and therefore meets the recent trends toward environmental sustainability. Zinc recyclability is not only an advantage for the final consumer, who can recycle products and appliances, but it is also an important factor of cost reduction for the die caster. In fact, if the agreements with customer allows it, zinc can be re-melted and, in controlled percentages, it can be reintroduced in the productive process with evident consequences in terms of reduction of scrap rate and of optimization of the productive processes.

If you wish to learn more about the possibility of recycling Zamak click here.
If you look for insights on zinc circular economy we suggest you to read Zinc life cycle: how it contributes to circular economy.

Productive process optimization

In regards to cost reduction in die casting not only the properties of zinc are important but also the productive process with which the metal is manufactured. Die casting techniques and machineries have to be up to date with technological development in order to be efficient, for this reason constant research and innovation are necessary. It is also important to have effective supply chain and logistic managment, if you want to learn more click here.

For a general overview about these topics we suggest you to read the article Production process improvement in the die casting industry. If you wanto to deepen your knowledge on the  analysis necessary to optimize the productive process read the article How die casting companies can help you save time and budget.

Automation and cycle time

An important step to achieve cost reduction is, for example, the introduction of automation in the productive process. In fact, automation makes the system more efficient by diminishing the percentage of scrap and allowing the operators to deal with activities with a greater added value.

Moreover, the acquisition of automation is closely related to the capability of updating and implementing the productive machineries. Thanks to the purchase of new machineries activities that used to be manual become automatic with a resulting diminishing in lead time, cycle time and scrap rate and a noticeable increase in productivity. Cycle time, in particular, is very important in relation to cost reduction strategies: in fact diminishing cycle time means increasing OEE, the productive performance index of a plant, and, consequently, the production. In the specific field of hot chamber die casting the reduction of cycle time represents a further saving opportunity because, in a reduced cycle time, the thermal power that the melted material provides to the mold is increased with a resulting decrease of cold fronts and related defects.

If you want to learn more about automation and its importance for the production process read How automation helps improving the production process; if you want to discover more about cycle time and its optimization we suggest you to read How die casting cycle time optimization can help to reduce costs.

Simulation

Another strategy to optimize the productive process is to use simulation software that allow designers to forecast what is going to happen during the die casting process. Simulation is a useful instrument to prevent problems, errors and defects during the production of the die casts and it is, moreover, a fundamental aid during design, prototyping and testing phases.

You can find a study about the advantages of simulation in zinc die casting clicking here.

Quality certifications

A guarantee of optimization of the productive process and of the subsequent cost reduction is the achievement of quality certifications. Smeta 4 Pillars, for example, is a certification of qualitative standards, environmental management, company integrity, health and safety with a noticeable impact in terms of cost reduction. In fact, Smeta 4 Pillars through the sharing of standardized approaches improves and aligns the productive process safeguarding brand reputation and guaranteeing an ethical supply chain.

Co-design

Co-design consists in a series of activities aimed at increasing the value of the product and at improving it in terms of quality and efficiency. Often these activities do not result in an increase in production costs but, on the contrary, they result in a decrease in costs. Through co-design, if already implemented during designing phase, it is possible to agree with the customer on weight reduction, elimination of secondary operations, optimization of the mold and a number of other actions that directly lead to a noticeable cost reduction. Obtaining a drawing that is already optimized for mass production allows the customer to have a final product that is in line with expectations and with less risks and scraps. As a further assurance of cost reduction, already during co-design phase, it is possible to undertake a VA/VE value analysis and to optimize the process through the DFM. VA/VE value analysis is a method of problem solving that allows the effective identification of unnecessary costs making it possible to reduce them. DFM, Design for Manufacturability, is a feasibility study in which the design of the product is evaluated and in which adjustments, special treatments and structural modifications are proposed in order to make the optimization of the production possible.

For a deeper insight on co-design we suggest you to read the article Product design for die casting, if you want to deepen your knowledge on VA/VE read The zinc die caster impact on production costs reduction. 

The methods to implement cost reduction in zinc die casting and to optimize processes and products do not end here. However, by reading this article you should have had evidence of some important benefits of cost reduction.

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1. DESIGN FREEDOM

Zinc, more precisely zinc alloys (ZAMAK), is a material that allows the production of components having nearly any type of shape. Thanks to zinc it is possible to obtain very thin surfaces that could not be achieved with other materials, such as aluminum. This results in a wider freedom in the design of a component, with consequent uniqueness and distinctiveness of the produced piece. Zinc thus represents an exceptional metal for the manufacturing of components which result complex from a shape perspective.

The following table contains zinc and aluminum values of minimum wall thickness: 

By choosing zinc for the production of small appliances it is possible to achieve several advantages related to the quality of the components, as zinc alloys present stable shrinking and high resistance. For example, compared to plastic materials, zinc presents a better typical precision and a superior yield and tensile strength (Table 1): these features result in a higher design freedom, not to mention remarkable qualities of the final product.

Table 1 – Typical Precision, Yield Strenght and Tensile Strenght values for zinc and plastic materials

2. HIGH END AESTHETICAL TREATMENTS

Several superficial treatments can be applied on zinc alloys. Specifically, it is possible to enhance aesthetical characteristics of the components through treatments which transform the product and improve its finish. The main aesthetical treatments realizable on zinc are:

• Galvanic treatments: polished chrome finish, satin chrome finish, different colors finish
• Liquid Painting
• Powder coating
• Special treatments to avoid material wear

Furthermore, specific treatments that take advantage of the physical properties of the alloy can be realized on zinc components. Among the mentioned treatments, powder coating is a brilliant example of an aesthetical treatment achievable through powder electro-deposition and cooking at high temperatures (around 200°C). This type of coating permits to obtain a better texture to the touch compared to painting. Realizing this treatment on a zinc component lends to it a significant added value.
Materials treatments generally follow the trends of the reference sector. A limitless variety of solutions that can be applied to zinc can help to fulfil this variable requirement.

3. SUPPLIER’S SUPPORT

A customer that relies on a qualified zinc supplier can discover in its vertical experience the ability of working on design too and to recommend to its customers innovative layouts and special finishes. This service, known as co-design, is the collaboration between client and die casting supplier, which aims to realize a product with specific functions and mechanical features that is at the same time compliant with manufacturing processes. Co-design can help designers to deeply understand zinc properties and to fully take advantage of their supplier’s know-how.
Zinc is a versatile material that allows experimenting with shapes and designs, thus permitting the conception and creation of unique and original pieces. As zinc die casting represents a very vertical market, its suppliers have a deep and vertical knowledge of the subject and can support customers in the production of distinctive pieces. The adaptability of zinc alloys proves especially helpful as far as small appliances are concerned: whereas other products are more standardized and creative design is limited, small appliances turn out to be a suitable product to test zinc versatility. As they are composed of several components, it is possible to imagine a wide variety of solutions with the use of zinc alloys, thus implementing the appearance, the performance and the distinctiveness of a product.

4. CUSTOMER EXPERIENCE

A further aspect that has to be taken into consideration when selecting a material is the customer experience. The relationship between end user and product consists of several variables, such as performance and usefulness, but also visual appearance, texture and durability. Zinc components convey excellent perceptions in terms of visual impact and touch feeling. A product made of zinc is more likely to be perceived as clean, resistant and of top quality.
As regards these features, it is essential to consider that the consumer has access to the use of small appliances through handles and buttons. If the body of the product is made of plastic, the handle or the button should be made of zinc, in order to offer the user a different experience in the use of the product. These details enhance the customer experience and make the difference in the customer’s choice of a product.

5. CLEANING OF COMPONENTS

From the end user’s point of view the ease of cleaning of a product is an aspect that influences the purchasing choice. For example cleaning chromed zinc components is easier compared to other surfaces, because they present a hard, solid and smooth surface. A product with these characteristics simplifies the cleaning process, making it quicker and more efficient: this results in a benefit for the consumer. Not only chromed zinc components are easy to clean, but they also convey a perception of neatness and brightness that impacts on the consumer’s eye. These qualities make zinc components stand out compared to other surfaces.

6. ZINC RECYCLABILITY

Virtuous companies are increasingly looking for sustainability. To support a sustainable development it is advisable to use recyclable materials, one of which is zinc. Zinc alloys can be re-melted and re-used several times without detriment to their properties. Normally the use of re-melted zinc alloys is limited to roughly 50% and this enables to completely exhaust production scrap. Today the implementation of this recycling system allows recycling a great number of zinc die casting scraps. Zinc thus represents a material with very low toxicity, not energy intensive to produce and recyclable. These properties make zinc an “environmentally friendly” material. 

7. REDUCED LEAD TIME

Lead time is the period of time that a company needs to fulfill a customer’s request in terms of supply. Logically, a short period translates into quicker results and a more satisfied client. In order to achieve this condition, zinc represents an efficient material thanks to its reduced cycle time. As a matter of fact, lead time is a concept related to cycle time: the period of time required to complete the manufacturing of a product, including every single process that leads to the finished product. Considering the cycle time of a product it is therefore possible to assume its related lead time. By choosing zinc instead of other materials, such as aluminum and plastic, lead time will be shortened, resulting in a more efficient and quicker service.
As mentioned above, cycle times related to zinc alloys die casting are lower compared to cycle times of aluminum alloys and plastic materials. In the first case, aluminum is molded at significantly higher temperatures, therefore the cycle time is superior due to cooling range. As far as plastic is concerned, it has superior filling times.
Below a table indicating values of cycle times of zinc alloys, aluminum alloys and plastic materials.

Table 2 – Typical production speeds and Broad production speed range for zinc, aluminum and plastic materials 

CASE STUDY N.1

Bruschi produces several components for coffee machines. In this specific case a client has contacted Bruschi to realize a cup holder tray for a coffee machine. The tray has been entirely realized in zinc and completely chromed. The entire surface of the component is considered aesthetical surface because the exterior is visible to the user’s eye and the interior becomes visible when the consumer removes the plastic cover and has access to the internal part of the tray to clean it.

The chrome process is composed of preliminary phases for the piece preparation. Particularly, the component has to be cleaned and polished through the use of rollers, tapes and scraping material. It is necessary to clean the internal part of the component too. For this reason Bruschi has conceived some alterations to the technological process that have allowed the achievement of an equivalent result.

Bruschi managed to solve the problem and produced a cup holder tray made of ZAMAK, externally and internally chromed.

CASE STUDY N.2

In this second case a client has requested to Bruschi the production of chromed handles for coffee machines. The complexity of realizing this component lied in its layout, in productivity and in the superficial quality. The handle was a particularly critical component because the standard mold cavities layout did not allow achieving the performance and costs level demanded by the client. Thanks to the experience and the expertise of Bruschi’s designers, Bruschi has conceived an alternative method to supply the mold. Designers have thus created a new mold that was compliant with the criteria demanded. Thanks to the new layout costs and performance levels have reduced.

In conclusion, the use of zinc for the production of coffee machines components generates remarkable advantages. By preferring the employ of zinc it is possible to design and create a functional and aesthetical product, able to combine design freedom and high-end aesthetical treatments, together with a proper balance between costs and production levels.

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