How does zinc die casting compare to plastic or aluminum in exterior handle strength?

How Does Zinc Die Casting Compare to Plastic or Aluminum in Exterior Handle Strength?

Material Requirements for Exterior Handles

Exterior automotive and industrial handles must withstand repeated mechanical loads, resist environmental exposure, and maintain dimensional stability over time. Strength, stiffness, impact resistance, and finish durability are critical. Zinc die casting, aluminum casting, and high-strength plastics are all used depending on application demands, but their mechanical performance differs significantly.

Zinc Die Casting: High Strength and Rigidity

Zinc alloys such as Zamak 5 and Zamak 3 provide:

• Tensile strength: 280–330 MPa

• Yield strength: 220–280 MPa

• High hardness (HB 80–100)

• Excellent dimensional accuracy and low creep

• Ideal for compact handles with high structural load or locking mechanisms

Zinc die cast handles can integrate mounting points, fastener bosses, and textured surfaces in one piece, reducing assembly while increasing structural integrity.

Aluminum Die Casting: Lightweight with Good Strength

Aluminum alloys like A380 or A360 offer:

• Tensile strength: 275–310 MPa

• Lower density (~2.7 g/cm³)

• Moderate stiffness and good corrosion resistance

• Preferred for applications requiring weight reduction and thermal performance

Aluminum handles are strong but require thicker sections or added reinforcement to match zinc’s rigidity in compact designs.

Plastic (Engineering Thermoplastics): Lightweight but Lower Strength

High-performance plastics such as nylon (PA6, PA66) or polycarbonate blends are used for:

• Tensile strength: 60–120 MPa (glass-filled: up to 200 MPa)

• Density: ~1.2–1.4 g/cm³

• Excellent corrosion resistance and low weight

• Susceptible to UV degradation, creep, and deformation under high loads

Plastic handles are ideal for non-load-bearing applications or when cost and weight are critical, but they often require metal inserts for fastening or reinforcement.

Mechanical Comparison Table

Best Use Cases by Material

• Zinc: Compact, load-bearing exterior handles (e.g., vehicle doors, industrial equipment)

• Aluminum: Lightweight handles with larger surface area and moderate load (e.g., truck compartments, utility covers)

• Plastic: Non-structural exterior handles, often used in combination with metal reinforcements

Neway’s Exterior Handle Manufacturing Capabilities

Neway offers robust solutions for exterior handle production, including:

• High-strength zinc die casting for complex, load-bearing designs

• Lightweight aluminum die casting with integrated mounting features

• Durable surface finishing like powder coating or painting for UV and corrosion protection

• Complete tooling and rapid prototyping for new handle designs