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Zinc die casting with additive manufacturing - Zamak 5
3D printing with zinc
Components made from the zinc alloy Zamak 5 are widely used in industry. This material is established as the standard material for zinc die casting. This manufacturing process allows components to be produced economically in large quantities.
Molten metal is pressed into a prefabricated steel mould at high pressure. This master mould - the tool - determines the geometry of the component and is the biggest cost factor in zinc die casting; every change to the component geometry requires the tool to be adapted or even newly manufactured. In product development, prototypes are therefore only produced from the series material once the component geometry has been finalised as far as possible. This unnecessarily restricts the product development process.
PROTIQ is the first 3D printing provider in the world to have succeeded in developing a process for the additive processing of the series material Zamak 5, which overcomes the high time and cost expenditure typical of zinc die casting. In 2022, PROTIQ was therefore honoured with the award for "Intelligent Manufacturing" at the International Zinc Die Casting Competition.
What is Zamak? Introduction to a versatile material
Zamak refers to a family of alloys consisting mainly of zinc, reinforced by the addition of aluminium, magnesium and copper. This combination gives Zamak a range of favourable properties that make it attractive for various industrial applications.
Unique composition and properties
The main component of Zamak is zinc, which is known for its good castability and durability. Aluminium, the second most important element in the alloy, increases strength and hardness. Magnesium helps to improve corrosion resistance, while copper strengthens the mechanical properties and extends the service life of the alloy.
Wide range of applications
Zamak is used in many industrial sectors due to its excellent casting properties and mechanical strength. It is particularly suitable for the production of precision parts where strength, durability and a high-quality surface finish are required. Typical applications can be found in the automotive industry, in the manufacture of household appliances, in electronics and in decorative elements.
Zamak 5 - A popular variant
Within the Zamak family, Zamak 5 is particularly noteworthy. This variant contains a higher proportion of copper, which results in improved mechanical properties. The increased strength and durability make Zamak 5 ideal for demanding applications where above-average performance is required.
Areas of application
Automotive industry: In the automotive industry, Zamak 5 is used for the production of components such as door handles, emblems, mouldings and other decorative and functional parts. The alloy offers excellent surface quality and mechanical strength, which is crucial for automotive parts.
Electronic devices: In electronic devices, Zamak 5 is used in components such as housings, buttons and switches. The alloy is ideal for precision parts that require high strength and resistance to mechanical stress.
Toy industry: In the toy industry, Zamak 5 is used for the production of robust and durable components, especially for toys that have to withstand high stress.
Household appliances: In household appliances, Zamak 5 is used for parts such as handles, knobs and decorative elements. The alloy offers an attractive surface and durability, which are important for everyday items.
Household appliances: In household appliances, Zamak 5 is used for parts such as handles, knobs and decorative elements. The alloy offers an attractive surface and durability, which are important for everyday items.
Technical properties of Zamak 5
Tensile strength
218+/-40MPa
Elongation at break
1,5+/-0,5%
E-modulus
28+/-3GPa
Precision
+/-0,1mm
Minimum wall thickness
0.6mm
Classic zinc die casting
Zinc die casting is a precision process characterised by high efficiency and the ability to produce complex parts with high accuracy. The process begins with the melting of the zinc alloy, which is then fed into a die casting machine. In this machine, the molten alloy is injected under high pressure into a steel mould (the die casting mould). This mould is designed to replicate the exact geometry of the part to be produced.
Once the molten alloy is injected into the mould, it quickly solidifies, creating the desired part. The high pressure applied during the injection process ensures that the material fills all parts of the mould. This results in a high level of detail and good surface quality. After solidification, the mould opens and the finished part is ejected.
The zinc die casting process not only enables a high production speed, but also excellent dimensional accuracy and surface quality. This makes it ideal for the mass production of small to medium-sized parts, as required in the automotive industry, mechanical engineering and many other sectors.
Prototypes and series components from 3D printing
With the help of additive manufacturing, functional prototypes made of Zamak 5 with the properties of the subsequent series component can be produced at an early stage of product development. No expensive tools are required for this, as production takes place directly from 3D CAD data.
The workpieces from 3D printing can be electroplated as usual, for example to achieve a high-gloss chrome look. In contrast to zinc die casting, which only pays off from very large quantities, additive manufacturing enables the economical production of individual pieces and small series, so-called low-runners.
Thanks to the standardised and digitalised processes at PROTIQ, the Zamak 5 components are ready for delivery within just a few working days. This saves product developers weeks of waiting time and allows them to carry out meaningful tests much earlier.
In addition, any change to the 3D model can be applied to a new prototype quickly and cost-effectively, resulting in greater flexibility and significant added value in product development.
Advantages of 3D printing compared to zinc die casting
- Reduced time and costs
- Direct production based on the 3D model, without expensive tools
- Economical production from batch size one
From idea to series product - Zamak 5 in 3D printing
In comparison: Zamak 5 in zinc die casting
