#net shape

[independant-business]

Achieving Net Shape with Zinc Die Casting 

When to Choose Zinc Die Casting 

In die cast manufacturing, choosing the right material is an important first step in the design process. When considering the varied materials for your next design, zinc emerges as an option for a multitude of reasons. A key factor to consider is zinc's ability to achieve net shape in die casting. 

What Does Net Shape Mean? 

The concept of “net shape” is an important consideration in part design.   A typical goal in one’s part design is to include many features and geometry into a part and reduce the number of parts.   

Often fewer parts will result in a more effective design and lower cost solution since there is less to manufacture and join.  Ultimately, it is a better design and solution for all as there are fewer parts to buy, inventory, and assembly.    

The design of a zinc castings can align well with “net shape” objectives as this manufacturing process allows for feature designs that have various depths and is 3-dimensional vs a design of a stamping that is flat and limited.    

Achieving Net Shape with Fluidity 

One of zinc's standout characteristics is its remarkable fluidity when melted, it is similar to water. This property allows for the creation of parts that are complex and intricate and thus eliminating the need for extensive secondary operations or machining.   Zinc's versatility extends to its ability to accommodate tight corners and thin wall conditions. This makes zinc die casting an excellent choice for design flexibility. This feature empowers designers to bring intricate concepts to life. 

Easier Fastening and Joining of Parts  

Zinc casting can also incorporate fastening/joining features into the part and thus minimize or eliminate the need for welding or the use of additional screws, etc.    

For example, zinc die castings are well-aligned with industries requiring parts like fittings for fluid transportation.  Zinc alloy parts can have threads cast-in and thus minimizes the need for secondary machining, saving both time and resources.  Additionally, zinc part can have features designed in to act as a fastening rivet.  The material can be formed to provide a “staked” join and thus eliminate the need for a fastener all together.   

Strength Beyond Comparison 

Zinc stands strong among moldable materials, surpassing the strength of alternatives like plastic or aluminum. When you are striving to meet precise design specifications, zinc delivers the resilience required.   The decision to switch to zinc hinges on the specific needs of your products or parts. If strength, especially for tensile or fatigue, is a critical requirement, zinc is a common choice for improved performance. 

Cost-Efficiency for Complex Assemblies 

In situations where cost savings are crucial, consider the shift from steel stamping and welding to zinc die casting. As part usage increases, the cost justification for zinc die-cast parts becomes increasingly evident. Integrating essential details directly into the part streamlines the process. 

Zinc processes faster than other materials, enabling you to produce parts more quickly. Therefore, impacting the bottom line of a design compared to other materials. 

Investigate the Potential 

For manufacturers seeking cost reduction, improved quality, or decreased reliance on secondary operations, it is worthwhile to explore zinc.  

Dave Magner, Director of Sales, and Marketing at Deco Products was interviewed on the video podcast, Small Business Talks. Dave provided insights into the zinc die casting process. He emphasizes the advantages of Zinc, such as its strength, fluidity, and net shape capabilities. Listen here: https://www.podbean.com/ew/pb-3a3fz-154e6d7  

High-volume parts are particularly suitable for zinc casting, given its exceptional tooling lifespan compared to aluminum. 

Size Matters 

While zinc can accommodate parts up to 24 inches in length, it is especially ideal for those weighing under a pound. For smaller parts, around four inches or less, zinc is well suited. 

Deco's Expertise in the Design Process 

For manufacturers without designers experienced in zinc die casting, Deco Products can help. Our team of experts can guide you through the design process. Ensuring your products meet the highest standards of quality and efficiency. 

In conclusion 

When considering zinc for die casting, focus on its fluidity, design flexibility, strength, and alignment with your industry needs. Explore how zinc can optimize your manufacturing process, reduce costs, and enhance product quality.  

With Deco Products by your side, you can confidently navigate zinc die casting and gain the full potential for your projects. 

Zinc Die Casting Services 

As a leading manufacturer of zinc die cast products made in the USA. Deco Products understands the importance of the zinc die casting process in the manufacturing industry. With our social responsibility and commitment to sustainable manufacturing.  

We have the capacity to partner with you on your next zinc die cast project. Our team of highly skilled professionals provides the highest quality products and value-added services to our clients. 

Visit our capabilities and services page to learn more.  

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