Zinc Die Casting Component Design Guide

producing zinc die casting components to meet the demands of some specifications in many fields, firstly we will consider that a Zinc Die Casting Components Design Guide is indispensable. Complying with the guideline, Our workers can create high effective, cost-effective, and reliable zinc die-cast parts.

Zinc Die Casting Components Design Guide

Zinc die casting components design should follow hot chamber die casting, which provide high precision, small and medium size metal castings in high volume production under fast cast cycle. By Hot Chamber Die Casting Machine Produces High Quality Zinc Casting Parts .These small casting parts design will comply with the below steps to proceed.

No.1 Material Selection for Zinc Die Casting

Understand any specific requirements, including cast part structural, aesthetic, or functions. Choose the zinc alloy that best suits the component’s function and applications. Hereby we focus on the most common zinc alloys, Zamak alloys, which have different properties respectively. The common several types of them are listed as the follow.

Zamak And ZA Alloys

No.2 Consider Die Casting Constraints

Wall Thickness : Design uniform wall thickness between 0.5mm to 5mm throughout the component to minimize defects and ensure structural integrity.
Draft Angles : Keep all vertical walls having a draft angle between 1° and 3°. This helps ejecting out of the part from the die.
Undercuts: Slides/Lifters can be used but add cost if possible. Post-casting machining or assembly.
Fillet Radii: Stress concentrators → use radii (R ≥ 0.5 mm), Minimum 0.3 mm radius to improve flow & reduce cracking.
Parting Line & Ejection: Parting Line Location: Should minimize flash & finishing work, Ejection Pins: Design to avoid visible marks on critical surfaces.
Ribs & Bosses: To reinforce the structural integrity of the part, add ribs without significantly increasing weight or material costs. Bosses designed is convenient to assemble and avoid thick sections that can cause shrinkage.
Surface Finish & Textures: Polished Molds: Can achieve smoother finishes, Textures: Possible but may require additional draft.
Post-Casting Considerations: Flash removal, machined by cnc machining and the coating of die castings.

No. 3 Optimization for Detail Design and The Die Improvement

Our engineers can access the aesthetic and functional needs of the die casting part, position the part line location and minimize impacting the part appearance. Place ejection pins in non-visible or non-functional areas to avoid marks on critical surfaces. Meanwhile control ejection pin push power avoid over push power to deform the part. Optimizing these optimal gates and vents to ensure efficient material flow and minimal air entrapment. and ensure the as-cast part high qulity.

No. 3 Optimization for Detail Design and The Die Improvement

Our engineers can access the aesthetic and functional needs of the die casting part, position the part line location and minimize impacting the part appearance. Place ejection pins in non-visible or non-functional areas to avoid marks on critical surfaces. Meanwhile control ejection pin push power avoid over push power to deform the part. Optimizing these optimal gates and vents to ensure efficient material flow and minimal air entrapment. and ensure the as-cast part high qulity.

No.4 Rapid Prototyping and Testing

Create a prototype to test functionality, fit, and performance before mass production in shorter time. Prototypes can be produced by precision casting die, If neccessary we can engage in further post-process like CNC machining, grinding, polishing or coating treatments to realize the functionalities of the cast part. Then begin to test its assembly and fit other components smoothly and identify its performance. The first samples testing should be addressed before moving to high volume quantity production.

No. 5 Final Design Adjustments

Engineer can adjustments based on testing results, improve design aspects like wall thickness, rib locations, or gate and vent places, until the qualified prototype is confirmed. Once the design is validated, finalize the die design and manufacturing parameters. Record these test result and part parameters, include of the part material, cast cycle time, cooling and solidification temperature and the pluger force power.