Custom Die Cast Zamak Components for Reliable Medical Device Housings
Fashion accessories and costume jewelry often feature complex shapes, fine detailing, and surface finishes that must endure repeated handling and wear. At the same time, these products require affordability, design versatility, and high production efficiency. Zinc alloy die casting, especially using Zamak grades, provides an ideal solution—offering both mechanical strength and superior moldability for mass-producing precision fashion components.
At Neway, we deliver custom zinc die casting services for the fashion industry, creating intricate, high-quality accessories that meet demanding aesthetic and performance requirements. Our expertise allows us to cast fine textures, integrated mechanisms, and plated finishes that mimic precious metals—at a fraction of the cost.
Why Zinc Die Casting is Ideal for Fashion and Jewelry Components
Zinc alloys such as Zamak 3, 5, and 7 are widely used for casting ornamental components due to their excellent castability, strength, and finish compatibility. Unlike plastic injection molding or machining, high-pressure zinc die casting allows the creation of detailed patterns, undercuts, and contours in a single cycle—without secondary shaping.
Key Performance Benefits
Tensile strength: up to 400 MPa (Zamak 5) for durability under tension and flex
Wall thickness: as low as 0.8 mm, supporting delicate design features
Surface roughness: Ra ≤ 1.2 µm achievable with tumbling or polishing
Dimensional accuracy: ±0.02 mm on fit-critical parts (e.g., snap clasps, pins)
Density of 6.6 g/cm³ provides a substantial, premium feel in accessories
The material’s non-magnetic, stable properties also make it ideal for skin-contact products, as it can be coated or plated to meet hypoallergenic requirements.
Common Applications in the Fashion Industry
Zinc die castings are used across a wide range of decorative and functional accessory types. These components often require complex geometries, surface embellishments, or high-volume production.
Component Type | Examples | Key Requirements |
|---|---|---|
Decorative Pendants | Medallions, logos, tags, emblems | Crisp detail, plating-ready surface |
Functional Closures | Buckles, clips, clasps, zippers | Mechanical strength, wear resistance |
Jewelry Frames | Earring bodies, bracelet links, brooch mounts | Dimensional accuracy, polishability |
Branded Elements | Nameplates, belt logos, bag hardware | Custom textures, clear branding, finish durability |
Costume Jewelry Cores | Plated ring bases, necklace components | Hypoallergenic coating, fine pattern reproduction |
Zamak Alloys for Jewelry and Accessories
Neway offers several Zamak alloys to suit different fashion accessory applications. These materials conform to ASTM B86 and ISO 301 specifications.
Alloy | Tensile Strength (MPa) | Elongation (%) | Surface Finish Quality | Ideal For |
|---|---|---|---|---|
Zamak 3 | 270–280 | ~10 | Excellent | General-purpose aesthetic castings |
Zamak 5 | 380–400 | ~7 | Good | Functional and load-bearing jewelry elements |
Zamak 7 | 260–275 | ~13 | Best for ultra-smooth parts | Thin, high-finish fashion details |
Zamak 7 is frequently used for parts requiring the best plating base or ultra-fine texture resolution.
Precision and Design Freedom
Zinc die casting allows exceptional detail reproduction and reliable assembly integration for fashion pieces.
Minimum feature height: 0.1 mm for logos or decorative lines
Text embossing depth: 0.2–0.5 mm with excellent legibility
Draft angle: as low as 0.5° for smooth extraction without flash
Tolerances: ±0.02 mm for snap fit, hinge, or sliding components
Shrinkage control: <0.4% for stable fit in multi-piece items
Designs with moving parts, such as spring-loaded clips or swivel hooks, can be cast with integrated hinges, drastically reducing assembly costs.
Finishing and Surface Enhancement Options
Surface appearance is critical in fashion accessories. Neway offers a variety of post-processing solutions that replicate luxury finishes or add protection against tarnish and abrasion.
Electroplating: nickel, gold, rose gold, black chrome, antique finishes
Powder coating: matte, satin, or textured colors for branding elements
Painting: color fill, UV coatings, soft-touch surfaces
Anodizing: Applicable for zinc-aluminum hybrid parts
Assembly: includes key rings, fasteners, clasps, chain links, or magnets
All finishes are RoHS-compliant and meet EU/US consumer safety standards for jewelry coatings.
Tooling, Lead Time, and Mass Production
Neway supports the rapid development of fashion accessory dies with flexible production volume options.
Tooling material: H13 steel hardened for intricate, multi-cavity molds
Tool life: up to 500,000 shots for Zamak 3 and 5
Lead time: 3–5 weeks including mold flow simulation and sample submission
Cycle time: 15–30 seconds depending on part size and cavity count
Batch size: from 5,000 to 500,000+ pieces monthly with mass production scalability
Rapid prototyping is available using low-pressure or soft tooling for early-stage design validation and photoshoot-ready samples.
Case Study: High-Finish Fashion Belt Buckle
A fashion accessory brand approached Neway to manufacture a zinc die-cast buckle featuring a custom logo, an electroplated antique brass finish, and an integrated spring-loaded locking mechanism. Requirements included:
Logo depth: 0.4 mm with edge radii < 0.2 mm
Surface finish: Ra ≤ 1.2 µm pre-plating
Spring retention tolerance: ±0.02 mm on hinge interface
Coating resistance: >300-hour salt spray test
Volume: 250,000 units per year
Neway developed a 4-cavity H13 steel die with internal slides for undercut locking features. The buckle core was electroplated and assembled with springs and clips in-house, delivering Class A appearance and long-term durability.
Why Fashion Brands Choose Neway
Neway provides a one-stop solution for high-volume, high-precision zinc die cast components:
Fine pattern reproduction and cosmetic-class surface finishes
In-house coating, polishing, and assembly to reduce lead times
ISO 9001:2015-certified processes with full traceability and batch control
Support for custom textures, logo etching, and finish matching
Fast shipping options for export markets across North America and Europe
From runway accessories to consumer market pieces, we help brands achieve signature designs with manufacturing reliability.
Conclusion
Zamak zinc die casting offers exceptional strength, detail resolution, and surface finish flexibility, making it the go-to method for producing stylish, functional, and durable fashion accessories and jewelry. At Neway, our vertically integrated production ensures creative freedom, quality control, and delivery speed—turning your accessory concepts into mass-produced realities.
To explore a custom fashion or jewelry casting project, contact Neway today.
Frequently Asked Questions
What surface finishes are available for zinc fashion accessories?
Can Zamak castings be safely worn against skin or plated with hypoallergenic metals?
What level of detail can be achieved in decorative logo elements?
How fast can molds be developed for seasonal accessory collections?
What is the most cost-effective Zamak alloy for high-volume fashion castings?
