What are the typical tolerances achievable in zinc die casting?
What Are the Typical Tolerances Achievable in Zinc Die Casting?
Dimensional Tolerance Capabilities
Zinc die casting is renowned for its ability to produce highly detailed and dimensionally stable components. This is largely due to zinc's excellent fluidity and low solidification shrinkage, typically around 0.6%. According to North American Die Casting Association (NADCA) standards, zinc die castings can routinely achieve very tight tolerances, making them ideal for applications requiring precise dimensions without extensive post-machining.
For general reference:
Feature Size Range | Typical Tolerance (As-Cast) |
|---|---|
0 – 25 mm | ±0.05 mm |
25 – 50 mm | ±0.08 mm |
50 – 150 mm | ±0.13 mm |
>150 mm | ±0.2 mm |
These tolerances apply to linear dimensions and may vary slightly depending on part geometry, wall thickness, and die condition.
Factors Influencing Tolerance Control
Material Choice: Zinc alloys such as Zamak 3 and Zamak 5 have consistent flow characteristics and minimal warping, which support stable and tight tolerances.
Tooling Precision: Tool steels like H13 and P20 are used to ensure dimensional stability across high-volume production runs.
Casting Conditions: Controlled injection pressure, die temperature, and cooling rate significantly impact the dimensional repeatability of parts.
Secondary Operations: Where even tighter tolerances are needed (e.g., ±0.01 mm), finishing methods such as post machining can be applied to meet strict functional requirements.
Geometric Tolerances
Beyond linear tolerances, zinc die casting also supports controlled flatness, roundness, and coaxiality. Features like holes, bosses, and internal slots can be cast to near-net shape with minimal deviation, reducing the need for additional finishing.
Recommended Services for High-Tolerance Zinc Components
To ensure the highest dimensional accuracy, we recommend the following:
Precision Casting Services
Zinc Die Casting: Capable of producing complex, high-tolerance parts with consistent quality.
Tooling and Die Support
Tool and Die Creating: High-precision dies made from wear-resistant tool steels to ensure long-term dimensional control.
Post-Processing and Inspection
Post Machining: Tightens tolerances for critical functional surfaces.
Die Castings Inspection: Dimensional validation through precision metrology tools and CMM.
For customers seeking precision zinc components with repeatable tolerances, our one-stop service solution offers integrated support from design through quality control.
