Custom Zamak Die Casting Service for Corrosion-Resistant Electrical Connectors

Electrical connectors must ensure signal integrity while withstanding harsh environments in demanding industrial, automotive, and consumer electronics applications. Connectors need mechanical resilience and corrosion resistance, whether exposed to vibration, moisture, temperature shifts, or chemical agents. Zamak zinc die casting offers a reliable and cost-effective solution for manufacturing durable connector housings with complex geometries and stable dimensional tolerances.

At Neway, we offer custom Zamak die casting services tailored to produce corrosion-resistant electrical connector housings, terminal blocks, backshells, and enclosure frames. Our zinc casting capabilities ensure optimal fit, sealing, and finish—while supporting both low- and high-volume production.

Why Zamak Is Ideal for Electrical Connector Components

Zamak alloys (Zinc-Aluminum-Magnesium-Copper) are ideal for connector housings due to their combination of strength, dimensional stability, surface quality, and corrosion resistance. High-pressure die casting enables the efficient production of high-precision connector parts that integrate multiple functions in a single shot.

Key Performance Benefits

• Tensile strength up to 400 MPa (Zamak 5)

• Dimensional tolerances of ±0.02 mm for precision mating interfaces

• Wall thickness as low as 0.8 mm with excellent structural rigidity

• High surface quality: Ra ≤ 1.6 µm after tumbling or polishing

• Corrosion resistance: up to 500 hours in salt spray (ASTM B117) with powder coating or plating

Zamak parts are non-magnetic, EMI shielding-compatible, and support high-volume automation for connector assembly lines.

Typical Applications for Zamak Connector Castings

Zamak die casting suits low-voltage and high-voltage electrical connector components across diverse sectors.

These components often feature undercuts, slots, threads, and strain relief geometry—all achievable through optimized die casting.

Zamak Alloys for Electrical Components

Neway offers multiple Zamak alloys, conforming to ASTM B86 and ISO 301 standards. Selection depends on the balance of strength, castability, and finish required.

Zamak 5 is particularly effective where mechanical locking and environmental durability are essential.

Dimensional Accuracy and Connector Fit

Precision is critical in electrical components, where misalignment can compromise sealing, electrical contact, or ease of installation.

• Wall thickness: 0.8–3.5 mm

• Flatness: ≤ 0.05 mm over 80 mm mating planes

• Hole tolerance: ±0.02 mm for threaded inserts or self-tapping screws

• Porosity level: <0.5%, verified via vacuum testing and X-ray inspection

• Ra ≤ 1.6 µm for post-finished connector surfaces

Neway uses multi-cavity tools and CMM inspection to maintain quality consistency across large connector programs.

Surface Finishing for Durability and EMI Protection

Neway provides a range of post-processing treatments that enhance corrosion resistance, conductivity, and appearance of electrical connector parts.

• Electroplating: nickel, tin, or zinc plating for conductivity and anti-corrosion layers

• Powder coating: provides insulation and protection in thicknesses of 60–100 µm

• Anodizing: optional for hybrid aluminum-zinc systems

• Painting: color-coded connector shells per industry standards

• Assembly: includes installation of gaskets, terminals, EMI springs, or threaded inserts

All treatments meet applicable ISO and RoHS environmental safety directives.

Tooling and Production Capabilities

Neway provides full in-house tool and die making, with tooling designs optimized for short- and long-run programs.

• Die steel: H13 tool steel for 250,000–500,000 cycle tool life

• Tooling lead time: 4–6 weeks with mold flow simulation and DFM validation

• Production cycle time: 25–40 seconds per connector housing

• Part sizes: from <10 mm up to 150 mm in length

• Support for low-volume manufacturing and mass production

We also offer rapid prototyping for functional testing of connector fit, sealing, and locking features.

Case Study: Industrial IP67 Power Connector Housing

A client in the industrial automation sector required corrosion-resistant housing for a high-current connector used in outdoor installations. Requirements included:

• IP67-rated sealing

• Corrosion resistance: >500 hours salt spray

• Machined tolerances: ±0.02 mm for O-ring groove and threaded interface

• Electroplated finish for conductivity

• Annual volume: 200,000 units

Neway selected Zamak 5 for optimal strength and corrosion resistance. A 4-cavity tool was used to optimize cost per part. Post-casting CNC machining refined the seal area, and nickel plating was applied to meet electrical conductivity and corrosion standards. The program achieved 98.7% first-pass yield and passed IEC 60529 testing.

Why OEMs Choose Neway for Zamak Electrical Connector Casting

Neway offers full-service Zamak die casting for connector and electronic enclosure applications:

• End-to-end control from design, casting, finishing, to assembly

• Certified ISO 9001:2015 production

• IMDS, PPAP, and RoHS documentation provided

• Flexible tooling strategies for pilot and large-scale production

• High reliability and corrosion performance in rugged operating conditions

Whether you're producing power connectors, sensor plugs, or communication terminals, Neway delivers casting precision and surface integrity you can trust.

Conclusion

Zamak die casting provides a robust, cost-effective solution for producing corrosion-resistant, high-precision electrical connector housings. With dimensional accuracy, EMI compatibility, and a wide range of finishing options, Zamak parts are ideal for both industrial and consumer electronic applications. Neway combines tooling, casting, and finishing expertise to help manufacturers scale from prototype to global deployment with complete confidence.

To discuss your custom connector project, contact Neway today.

Frequently Asked Questions

1. What Zamak alloys are best suited for electrical connector applications?

2. How does zinc die casting improve EMI shielding in enclosures?

3. Can die cast connector housings meet IP67 or higher sealing standards?

4. What plating options are available for corrosion protection?

5. What is the production lead time for new connector die cast tooling?