Zinc Alloys: an Under-Exploited Technical Alternative to Aluminum

Tolerances, Thin Walls, tool's durability: Discover Where Zinc Alloys Outperform Aluminum Alloys

Zinc alloys (Zamak) are less well known than aluminum alloys, yet in many applications their mechanical, dimensional, and economic performance is superior—at a lower overall cost, both in manufacturing and investment.

From a mechanical standpoint, zinc offers tensile strength (Rm) of 280 to 400 MPa and yield strength (Re) of 210 to 320 MPa, compared with approximately 150 to 250 MPa (Rm) and 120 to 180 MPa (Re) for aluminum.

Zamak die casting also stands out for its ability to produce very thin walls—down to 0.5 mm—versus 1.2 to 1.5 mm for aluminum. This combination of strength and “fineness” enables more compact and durable parts.

Above all, it allows extremely tight dimensional tolerances to be achieved directly out of the mold, often impossible to reach with aluminum without secondary machining operations.

In production, cycle times can be up to twice as fast, using smaller presses. Finally, the carbon footprint can be up to four times lower, and mold life up to ten times longer, making zinc an industrial choice that is both high-performance and sustainable.