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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.
DECO offers a wide range of die casting capabilities and services. From Assembly to Zinc plating, and everything in between.
Small Independent Truck Repair Company Takes on Big Dealerships
It always takes someone with a new idea or to fill a gap customers want but isn’t being offered by others. We all love the stories with a David and Goliath element in them, well that was the case with our first independent business. Scott Noga owned and operated a trucking business in Southwestern Pennsylvania for many years. One of his pet peeves was dealing with large truck dealerships whenever one of his rigs needed service. The big truck dealers had a lot of overhead with big fancy showrooms and waiting rooms and there was always the problem of trying to get an appointment quickly. Scott believed there should be a basic truck repair service that offered the same parts and level of service as the big dealerships but in a smaller facility to help reduce overhead.
Opportunity found Scott when a local truck repair center came up on the market. He bought the business to spend time and money to hire trained technicians and mechanics and upgrade their equipment to current service standards. It wasn’t easy because many of his competitors had the budgets and the capitol to market and advertise there dealerships in a big way across many media channels.
Scot started out on a grass roots level doing basic marketing as well as old fashioned referrals and slowly building a good and solid reputation for quality service that was cheaper than a dealership and able to help truckers get appointments quickly.
He started Noga Services as a truck and trailer repair service for Southwest Pennsylvania on a busy truck route just outside of Elizabeth, PA and focuses his attention on heavy duty trucks and commercial trailers as well as adding state and FHWA inspections and finally adding preventative maintenance.
It just goes to show that an idea based on personal experience can lead to creating a solution for many other people who had the same problem. I have met Scott and am impressed with how dedicated he is to building his business and his reputation for good work. It takes a lot to make your dream or idea come true but is good to see when it comes together and encourages other small businesses to keep at it.
Neal has over 25 years of experience in economic development, sales and marketing, teaches SEO and analytics through CIRAS at Iowa State University and lives in Pittsburgh, PA. Neal has a passion for small business and small manufacturing companies and seeing them grow.
