Zinc alloy die casting molds

Core Product & Service: Zinc Alloy Die Casting Mold Design & Fabrication

Our core business focuses on the customized design and manufacturing of high-precision zinc alloy die casting molds, which are core production equipment for realizing integral forming of zinc alloy components via high-pressure die casting technology. Zinc alloy’s inherent advantages (low melting point, excellent fluidity, high strength-to-weight ratio) make it ideal for high-precision, complex small-to-medium sized components. Our core function is to deliver durable, high-performance die casting molds that maximize zinc alloy’s properties—ensuring uniform melt filling, tight dimensional control, and smooth surface finish of cast parts, which are critical for components demanding precise assembly, corrosion resistance, and aesthetic appearance. Backed by a professional team of 45+ engineers and technicians, we leverage advanced CAD/CAM/CAE software (UG, AutoCAD, SolidWorks) to conduct in-depth simulation of the zinc alloy die casting process. This includes simulating melt flow, heat transfer, and solidification to optimize mold cavity structure, gating system, exhaust layout, and cooling design, thereby preventing common defects such as porosity, shrinkage, and oxidation inclusions. Our molds are tailored to match the properties of various zinc alloy materials (e.g., Zamak 3, Zamak 5, Zamak 7, ZA-8) and the mass production needs of different industries, featuring exceptional wear resistance, stable casting performance, and extended service life.

Production Process & Supporting Technologies

The production of our zinc alloy die casting molds adheres to a strict industrial-grade standardized workflow, optimized for zinc alloy’s unique casting characteristics (low melting point: 419-450℃): 1. Demand Analysis & Design (Collaborate with clients to confirm component specifications, performance requirements, zinc alloy material selection, and production capacity; conduct 3D mold modeling and CAE die casting process simulation to verify melt filling uniformity, structural integrity, and defect risk);2. Raw Material Preparation (Select high-quality die casting mold steel (H13, SKD61, P20) with superior wear resistance and thermal stability, suitable for zinc alloy’s low-temperature casting process; implement precision cutting via CNC flame cutting equipment); 3. Precision Machining (Perform CNC milling, grinding, EDM, wire cutting, and high-speed machining to ensure the machining accuracy of mold cores, cavities, and gating components, with key dimensions controlled within ±0.005mm; focus on mold surface finish to enhance the aesthetic quality of zinc alloy cast parts); 4. Assembly & Debugging (Skilled technicians conduct manual assembly, install temperature control systems and high-efficiency exhaust components, and perform multiple rounds of debugging on die casting machines to optimize parameters such as injection speed, pressure, and mold temperature (150-200℃) for zinc alloy’s low melting point); 5. Quality Inspection & Delivery (Use coordinate measuring machines (CMM), X-ray flaw detectors, and hardness testers to inspect mold dimensions and internal quality of trial castings; conduct performance tests (corrosion resistance, tensile strength) to ensure compliance with industrial standards and provide detailed test reports). In addition to die casting mold design and fabrication, we also offer supporting processes such as post-casting machining (milling, drilling, tapping), surface treatment (electroplating, passivation, powder coating), and finished product assembly, delivering a full-chain one-stop service to clients. We also provide related processes such as aluminum alloy die casting and plastic injection molding to meet diversified client needs.

Common Problems & Solutions in Zinc Alloy Die Casting Mold Design & Fabrication

• Problem 1: Porosity and shrinkage in zinc alloy castings - Solution: Utilize CAE simulation to optimize the mold’s exhaust system, adding exhaust ports in gas-trapping areas to discharge air and zinc vapor; Adjust die casting parameters (reduce injection speed appropriately, increase holding pressure) to improve melt density; Control zinc alloy melting temperature (430-440℃) to avoid excessive gas absorption; Use high-purity zinc alloy materials and conduct degassing treatment before casting.

• Problem 2: Oxidation inclusions and surface defects - Solution: Optimize the gating system to minimize zinc alloy melt contact with air; Install a protective gas device (e.g., nitrogen) during casting to prevent oxidation; Enhance mold surface finish and apply anti-stick coating to reduce surface friction; Strictly control the cleanliness of the mold cavity and zinc alloy melt.

• Problem 3: Dimensional deviation and warpage of cast parts - Solution: Enhance mold machining precision, controlling key dimensions within ±0.005mm; Optimize the cooling system layout to ensure uniform cooling of the mold and reduce thermal deformation of cast parts; Adjust holding pressure and cooling time to compensate for zinc alloy shrinkage; Conduct multiple rounds of trial casting and dimensional calibration to ensure mold stability.

Frequently Asked Questions (FAQ)

• Q1: What types of zinc alloy die casting molds can you design and fabricate? - A1: We can customize die casting molds for various zinc alloy components across industries, including automotive hardware (door handles, lock cores), 3C electronic parts (connector housings, heat sinks), consumer goods (toy parts, hardware accessories), and industrial instruments (sensor housings, valve cores). We support customization based on client-specific drawings and performance requirements (e.g., precision assembly, corrosion resistance, aesthetic appearance).

• Q2: What is the lead time for custom zinc alloy die casting molds? - A2: Lead time varies by mold complexity: Sample molds take 8-18 working days (shorter than aluminum alloy molds due to zinc’s low-temperature casting advantage), mass production molds take 22-45 working days, and urgent orders can be completed in 6-12 working days with an additional fee. We will provide a detailed production schedule and confirmed delivery time upon order confirmation, ensuring alignment with your production plan.

• Q3: Do you provide quality assurance for your zinc alloy die casting molds? - A3: Yes, we offer a 12-month quality guarantee for all zinc alloy die casting molds. During the guarantee period, if quality issues arise due to mold design or manufacturing (e.g., dimensional deviation, abnormal wear, casting defect recurrence), we will provide free repair or replacement services. We also offer lifelong technical support for mold maintenance and die casting parameter optimization.

• Q4: Can you provide one-stop services including die casting production of finished zinc alloy parts? - A4: Yes, we are equipped with 20+ high-pressure die casting machines (80-800 tons) optimized for zinc alloy casting, as well as a professional post-processing workshop. We can provide integrated services from mold design, fabrication to finished product die casting, machining, surface treatment, and assembly, effectively reducing your communication costs and shortening the production cycle.

• Q5: What certifications do your molds and finished zinc alloy products hold? - A5: Our factory is certified by ISO9001:2015 and IATF16949 (automotive industry quality management system). The zinc alloy materials we use comply with ASTM B86, EN 1774, and RoHS standards. We can provide relevant certification documents, material safety data sheets (SDS), and performance test reports (corrosion resistance, tensile strength) according to client requirements.

Product Classification & Technical Specifications

1. Product Classification by Industry, Material & Part Type

2. Technical Specification Parameters

Our Core Competitiveness

• 10+ Years of Zinc Alloy Die Casting Expertise: Founded in 2012, we have focused on zinc alloy die casting mold design and fabrication, serving over 200 clients from more than 40 countries, including Europe, North America, and Southeast Asia. Our profound industry experience enables us to accurately grasp the unique technical requirements of zinc alloy casting and the quality standards of diverse global industries.

• Professional Technical Team: A team of 45+ engineers and technicians with an average of 8+ years of experience, proficient in zinc alloy die casting mold design, CAE simulation, and process optimization. They excel in solving complex technical issues such as high-precision zinc alloy molding, defect control, and material compatibility matching.

• Strong Production Capacity: Our 8,000-square-meter factory is equipped with 50+ sets of advanced production and testing equipment, including CNC milling machines, EDM machines, wire cutting machines, CMM, high-pressure die casting machines optimized for zinc alloy, and X-ray flaw detectors. We have an annual production capacity of 100+ sets of die casting molds.

• Strict Quality Management System: Certified by ISO9001:2015 and IATF16949, we implement full-process quality control from raw material inspection to finished product delivery. Our professional quality inspection team and complete testing equipment (corrosion test chambers, tensile testing machines) ensure product stability and compliance with international standards.

• Improved Supply Chain: We cooperate with reliable domestic suppliers to ensure stable supply and consistent quality of high-purity zinc alloys and mold steel. By integrating upstream and downstream resources, we achieve cost optimization and timely delivery, effectively supporting clients' mass production plans.

• Global Service Capabilities: Partnering with renowned international logistics companies (Maersk, COSCO), we leverage Qingdao Port's geographical advantage to provide efficient and safe global shipping. We offer 24-hour online technical support and a 12-month quality guarantee, promptly addressing after-sales issues for global clients.

Customer Case: Zinc Alloy Die Casting Mold Project for European 3C Client

Our client is a leading 3C electronic device manufacturer in Germany, specializing in high-precision connectors. They faced challenges with their original zinc alloy connector housing die casting molds: dimensional deviation (exceeding ±0.03mm) caused poor connector insertion performance, and surface oxidation inclusions affected electroplating quality. Additionally, low production efficiency (only 350 housings per day) hindered their ability to meet market demand. In 2023, they partnered with us to customize high-precision die casting molds for their new-generation connector housings.

Our technical team first conducted a detailed analysis of the client’s connector housing drawings and performance requirements (dimensional accuracy ±0.01mm, smooth surface for electroplating, and compliance with RoHS standards). Using UG software, we built a 3D mold model and performed CAE simulation to optimize the mold’s gating and exhaust systems—adopting a pinpoint gating design to ensure uniform melt filling and adding 28 micro-exhaust ports to eliminate gas trapping and oxidation. We selected H13 mold steel and implemented a strict surface polishing process (Ra ≤ 0.05μm) to enhance the cast part’s surface finish. For the zinc alloy material, we recommended Zamak 5 with excellent strength and electroplating performance. During debugging, we adjusted die casting parameters (injection temperature 435℃, mold temperature 180℃) multiple times and conducted dimensional inspection and electroplating compatibility tests on trial castings.

The final delivered molds achieved outstanding results: Dimensional accuracy of the connector housings was controlled within ±0.01mm, surface oxidation inclusions were completely eliminated, and electroplating pass rate reached 99.8%; production efficiency increased to 1,200 housings per day, and the mold service life was guaranteed to exceed 2 million shots. The client highly recognized our product quality and technical expertise, signing a long-term cooperation agreement covering multiple 3C component molds.

Why Choose Qingdao Xinlongji?

1. Professional Focus on Zinc Alloy Die Casting: We specialize in zinc alloy die casting mold design and fabrication, with in-depth insights into zinc alloy’s unique properties and industry standards across automotive, 3C, and consumer goods sectors, ensuring solutions that precisely match client needs.

2. One-Stop Integrated Service: From mold design and fabrication to finished product die casting, machining, and assembly, we streamline the supply chain, reducing your communication and management costs. We also offer supporting processes for other materials to meet diversified demands.

3. Proven Technical Strength: Our advanced CAE simulation technology and professional engineering team effectively solve complex zinc alloy die casting challenges (e.g., high precision control, oxidation prevention), ensuring product quality and production efficiency.

4. Reliable Quality Assurance: International quality certifications and full-process quality control ensure our products meet global standards, minimizing production risks and facilitating your entry into international markets.

5. Efficient Global Support: With rich international trade experience and mature global logistics channels, we guarantee timely delivery. Our 24-hour technical support team addresses after-sales concerns, providing peace of mind throughout production.

Qingdao Xinlongji Metal Manufacturing Co., Ltd. is committed to becoming a trusted partner in the global zinc alloy die casting mold industry. We look forward to collaborating with you to create greater value for your business! For more information on our products and services, please feel free to contact us.