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Zamak 5 in 3D Printing: The Zinc Die Casting Alloy Without Tooling
Zamak 5 is the standard material in zinc die casting. PROTIQ is the world's first 3D printing service provider to develop a process for processing Zamak 5 by selective laser melting (SLM). This makes it possible to produce functional prototypes, one-offs, small batches and spare parts from the series material – without a die casting tool, directly from CAD data and within a few working days.
In 2022, the process was honored with the "Intelligent Manufacturing" award at the International Zinc Die Casting Competition. Upload your 3D data to the PROTIQ Marketplace, choose Zamak 5 and see the price and delivery time right away.
- world's first3D printing service provider with a process for Zamak 5
- from batch size 1without a die casting tool
- 218 ± 40 MPatensile strength (as built)
- award-winning"Intelligent Manufacturing" 2022
Why 3D printing?
Why 3D print Zamak 5 instead of die casting it?
In zinc die casting, molten metal is pressed into a steel mold under high pressure. This tool is the biggest cost factor – and every change to the geometry requires the tool to be modified or remade. 3D printing needs no tooling and produces parts directly from CAD data.
With large quantities, the tooling costs are spread across many parts; with small batches, they become a cost problem. In product development, prototypes made from the series material are therefore usually only produced once the geometry is largely final – and then changes are hardly possible.
With 3D printing, functional prototypes made of Zamak 5 can be produced in early development phases – with the material properties of the later series part. Every change to the 3D model can be implemented quickly and cost-effectively in a new prototype.
Benefits of 3D printing with Zamak 5
- No die casting tool – cost-effective from batch size 1
- Functional prototypes made of the series material in early development phases
- Parts ready for delivery within a few working days
- Hardly any geometric restrictions – no parting lines, ejectors or draft angles
- Can be electroplated, for example for a high-gloss chrome finish
Comparison
Zinc die casting or 3D printing – when is which worthwhile?
3D printing is not a replacement for zinc die casting, but a complement: for large series, die casting remains the more economical solution. For prototypes, one-offs, small batches, low runners and spare parts, 3D printing is faster and more cost-effective because no tool is needed.
| Zinc die casting | 3D printing (SLM) | |
|---|---|---|
| Requirement | Die casting tool (steel mold) | 3D file |
| Start of production | Only after the tool has been made | Directly after the order is placed |
| Changes | Little scope, the tool must be modified | Possible at any time in the 3D model, up to series maturity |
| Cost-effective for | Large series | One-offs, prototypes, small batches, low runners |
| Unit price for large series | Drops sharply | Does not drop to the same extent |
| Geometry | Restrictions due to parting lines, ejectors and material accumulations | Almost unrestricted, including internal structures |
| Surface | Smoother | Rougher, but easy to post-process and electroplate |
From idea to series product – Zamak 5 in 3D printing
Material
What is Zamak 5?
Zamak is a family of zinc alloys with aluminum, magnesium and copper. In addition to around 4% aluminum, Zamak 5 contains around 1% copper and is established as a standard material in zinc die casting.
Zinc provides good castability and durability, aluminum increases strength and hardness, magnesium improves corrosion resistance and copper further increases strength. Zamak 5 is used wherever precise parts with good strength and a high-quality surface are required – for example in vehicle parts, connectors, fittings for windows and furniture, household appliances and electronics housings.
↑ Back to overviewProperties
What properties does 3D-printed Zamak 5 have?
According to the PROTIQ data sheet, laser-melted Zamak 5 achieves a tensile strength of 218 ± 40 MPa and a yield strength of 185 ± 15 MPa at a density of 6.2–6.4 g/cm³. The minimum wall thickness is 0.6 mm, the accuracy ± 0.7% (min. 0.1 mm).
| Property | Zamak 5 (as built) |
|---|---|
| Tensile strength | 218 ± 40 MPa |
| Yield strength Rp0.2 | 185 ± 15 MPa |
| Elongation at break | 1.5 ± 0.5% |
| Modulus of elasticity | 28 ± 3 GPa |
| Density | 6.2–6.4 g/cm³ |
| Thermal conductivity | 85 W/(m·K) |
| Accuracy | ± 0.7% (min. 0.1 mm) |
| Minimum wall thickness | 0.6 mm |
| Roughness after sandblasting | Ra 4–6 µm, Rz 25–35 µm |
Surface and finishing
3D-printed surfaces are rougher than cast ones, but can be post-processed well. After polishing, Zamak 5 parts can be electroplated as usual – for example for a high-gloss chrome finish.
↑ Back to overviewApplications
What is 3D-printed Zamak 5 suitable for?
For functional prototypes, small batches and low runners, series ramp-up, spare parts and customized parts – wherever a die casting tool is not, or not yet, worthwhile.
Functional prototypes
Tests with the series material in early development phases – without a prototype tool.
More about prototyping
Small batches and series ramp-up
Produce one-offs, small batches and low runners cost-effectively – or bridge the time until the die casting tool is ready.
Classic cars and spare parts
Handles, emblems or trim parts made of zinc die casting are often no longer available. 3D printing produces them from the original material, and they can be chrome-plated.
More about spare parts
Customized parts
Product variants or lettering in series – without a new tool for each variant.
Award
Award-winning: "Intelligent Manufacturing" 2022
For its process for the additive processing of zinc, PROTIQ was honored with the "Intelligent Manufacturing" award at the International Zinc Die Casting Competition in 2022.
The jury of the international competition, which took place as part of the European Zinc Die Casting Conference in Koblenz, recognized that the process helps the zinc die casting industry to open up new business areas.
↑ Back to overview
Free download
Brochure on Zamak 5
The brochure "3D printing with the zinc alloy Zamak 5" summarizes the information on this page, lists the properties of Zamak 5 and gives an overview of our offer.
↑ Back to overviewFAQ
Frequently asked questions about Zamak 5 in 3D printing
Can Zamak 5 be 3D printed?
Yes. PROTIQ is the world's first 3D printing service provider to develop a process for processing the zinc die casting material Zamak 5 by selective laser melting (SLM). In 2022, the process was honored with the "Intelligent Manufacturing" award.
What is the difference between zinc die casting and 3D printing with Zamak 5?
Zinc die casting requires a steel tool and is worthwhile above all for large series. 3D printing produces parts directly from CAD data without tooling and is therefore faster and more cost-effective for prototypes, one-offs, small batches and spare parts. Die-cast parts have a smoother surface; 3D-printed parts are rougher but can be post-processed well.
What properties does 3D-printed Zamak 5 have?
According to the PROTIQ data sheet, laser-melted Zamak 5 achieves a tensile strength of 218 ± 40 MPa, a yield strength of 185 ± 15 MPa, an elongation at break of 1.5 ± 0.5% and a modulus of elasticity of 28 ± 3 GPa at a density of 6.2–6.4 g/cm³.
Can 3D-printed Zamak parts be chrome-plated?
Yes. After polishing, the parts can be electroplated as usual, for example for a high-gloss chrome finish.
From what quantity is 3D printing with Zamak 5 worthwhile?
From batch size 1, because no tool is needed. For large series, zinc die casting remains more economical, as the unit price there drops sharply with quantity.
How quickly can I get Zamak 5 parts?
Thanks to standardized and digitalized processes, Zamak 5 parts from PROTIQ are ready for delivery within a few working days.
How do I order Zamak 5 parts?
Upload your 3D data in the configurator, choose Zamak 5 and the quantity – you will see the price and delivery time right away. If you have questions about your project, send our expert an e-mail.
↑ Back to overview
