Lightweight, precision die castings for complex aerospace components requiring tight tolerances and repeatable quality.

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Aerospace

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Die casting enables lightweight components through thin walls and optimized geometries, helping aerospace manufacturers reduce component weight while maintaining the strength and performance required for demanding applications.

Lightweighting

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High-pressure die casting can produce intricate geometries, thin sections, and tight tolerances in a single component, reducing the need for machining and simplifying complex aerospace assemblies.

Complex, Precision Components

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Precision tooling and highly controlled die casting processes deliver consistent dimensions and repeatable part quality across high-volume production, supporting stringent aerospace requirements.

Repeatable Quality

Die casting can consolidate components, minimize secondary operations, and reduce material waste, helping lower overall manufacturing costs while supporting scalable production.

Cost & Production Efficiency

Aerospace Leaders Choose Dynacast To Help Achieve Key Goals

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<p>Today’s customers are hungry for innovation. They want smart, lighter, tougher products and they want them now. Manufacturers must rise to the challenge again and again, rethinking their products, their processes, their whole markets. And when you’re faced with creating the future every single day, you need a partner you can trust—<a href="/about-us/company-overview" target="_self">Dynacast</a> is that partner.&nbsp;</p><p>For over 80 years, we’ve created, defined, and refined the technologies and processes that have revolutionized the world of precision metal components. We work with the <a href="/industries" target="_self">most demanding manufacturers across industries</a>, providing the expertise to help them solve their most complex challenges wherever they are in the world. We do it with exacting quality, an unparalleled scale and without compromise. There has never been a more challenging, more innovative, more awesome time to be in manufacturing. The future is here and we are proud to be apart of it!</p>

Dynacast Die Casting Manufacturer

Today’s customers are hungry for innovation. They want smart, lighter, tougher products and they want them now. Manufacturers must rise to the challenge again and again, rethinking their products, their processes, their whole markets. And when you’re faced with creating the future every single day, you need a partner you can trust—Dynacast is that partner. For over 80 years, we’ve created, defined, and refined the technologies and processes that have revolutionized the world of precision metal components. We work with the most demanding manufacturers on the planet, providing the expertise to help them solve their most complex challenges wherever they are in the world. We do it with exacting quality, an unparalleled scale and without compromise. There has never been a more challenging, more innovative, more awesome time to be in manufacturing. The future is here and we are proud to be apart of it!

<p>When designing components and selecting the right material, most engineers focus heavily on the weight of the material, which is why zinc is often overlooked when it comes to lightweight die casting applications. Many applications require parts to be lighter—especially in <a href="/industries/automotive" target="_self">automotive</a> and <a href="/industries/consumer-electronics" target="_self">handheld device</a> applications—so engineers choose aluminum or magnesium when really, zinc could be a more economical choice. At a quick glance one would assume that there is no place for zinc in lightweight applications, but if we look at the entire die casting process as a whole, can the pros outweigh the cons when it comes to lightweight zinc components?</p><h2>Castability</h2><p>Zinc is the most fluid of all alloys; it is no wonder die cast manufacturers like working with it. What most engineers don’t realize is that because of zinc’s greater fluidity, die castings can be made thinner, more intricate, and more complex, eliminating the need for secondary operations that are almost always necessary for aluminum and magnesium alloys. With less material being used in thin-wall applications, parts automatically become lighter, creating savings in material cost and energy—when melting and recycling.</p><h2>Extended Die Life</h2><p>One of the biggest upfront costs in die casting is the investment in <a href="/additional-capabilities/tooling" target="_self">quality tooling</a>. The tools used in the die casting process are usually heat-treated steel. The cost of tooling varies depending on the size and complexity of the component as well as the tooling type—conventional or multi-slide. Due to the low melting temperature of zinc die casting alloy, dies for zinc parts can last up to 10 times longer than dies used for aluminum and about five times longer than dies used for magnesium. When designing high-volume, complex components, zinc</p><h2>Cycle Time</h2><p>During the die casting process, molten metal is injected into the die to create the part. When the metal is solidified, the component is then ejected from the tool. Cooling time in the tool varies depending on the alloy and the size of the part and is often dictated by the size of the runner system. Zinc utilizes the hot chamber die casting process, which yields four to five shots per minute. Aluminum is a cold chamber die casting alloy only yielding two to three shots per minute. Since cycle time can determine up to 60 percent of the final part cost, using a zinc die casting alloy could offer added savings.</p><p><strong>Did you know that our proprietary multi-slide zinc die casting process can achieve upwards of 45 shots per minute?</strong></p><h2>Mechanical Properties</h2><p>Standard zinc alloys are stronger than aluminum and magnesium alloys at room temperature. Strength is inherent in the alloy itself and does not require secondary processing like most aluminum alloys—this saves on the overall cost per part.</p><p>EZAC is an alloy offered by Dynacast that is stronger and harder than any other die casting alloy. It is approximately 2.5 times stronger (yield strength) and 1.5 times harder (Brinell) than the most common aluminum die casting alloy, A380. With its zinc characteristics, EZAC is a great option for those seeking a high-strength, creep resistant alloy.</p><table><tbody><tr><td><p><strong>Material</strong></p></td><td><p><strong>Alloy</strong></p></td><td><p><strong>Yield Strength (0.2%)</strong></p></td><td><p><strong>Hardness</strong></p></td></tr><tr><td>&nbsp;</td><td>&nbsp;</td><td><p>PSI X 10^3</p></td><td><p>Brinell (HB)</p></td></tr><tr><td><p>Zinc</p></td><td><p>Zamak 3</p></td><td><p>32</p></td><td><p>82</p></td></tr><tr><td><p>Zinc</p></td><td><p>EZAC</p></td><td><p>57</p></td><td><p>120</p></td></tr><tr><td><p>Aluminum</p></td><td><p>A380</p></td><td><p>23</p></td><td><p>80</p></td></tr><tr><td><p>Magnesium</p></td><td><p>AZ91D</p></td><td><p>23</p></td><td><p>63</p></td></tr></tbody></table><p>Try our interactive metal selector tool to compare physical and mechanical properties of other die cast alloys.</p><p>Dynacast has over 80 years of experience in the die casting industry. Year after year our team of engineers improve and optimize our zinc die casting machines and our processes to provide the best, quality service to our customers all over the world. Contact our team today to learn more about our die casting capabilities and let us help you determine if zinc is the right fit for your next project.  </p><br /><p>&nbsp;</p>

Raw materials for the die casting process

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Explore the key benefits of zinc die casting including strength, detail, and cost efficiency for high-volume part production.

Benefits of Zinc Die Casting | Dynacast

Zinc die casting offers several advantages over aluminum and magnesium, including faster cycle times, longer die life, and comparable mechanical properties. 

Benefits of Zinc Die Casting

<p>Designed for innovation and agility, this 44,000 square foot die casting plant manufactured more than 70.3 million die cast parts in 2019 for a number of hardware industry sectors including electrical connectors and hardware, door lock components, window, furniture, household appliance, and industrial hardware.</p><p>Dynacast Montreal is a high-performing plant with a cross-functional, lean structure, and like most of our facilities, is successful because of its people. Here, there are specialists in <a href="/die-casting-technologies/machine-building" target="_self">die cast machines</a>, <a href="/additional-capabilities/tooling" target="_self">tooling design and manufacturing</a>, and casting processes as well. Virtually every step of the die casting process is housed in one place.</p><p>With high-volume programs driven by automation, an extensive array of in-house capabilities, and a localized supply chain mindset, Dynacast Montreal differentiates itself to offer the highest value of any</p><h2>Leading in manufacturing automation and die casting solutions</h2><p>Dynacast Montreal is better-positioned than any other supplier in the market to provide full die casting solutions for the <a href="/industries/hardware" target="_self">hardware industry</a>, in part because Montreal is home to Dynacast’s Techmire division. We have the capacity and expertise to produce die casting machines and tooling in-house, as well as optimize the die casting process.</p><p>With the three pillars of die casting all under one roof, Dynacast Montreal is able to leverage innovation in all stages of the production environment to deliver precision hardware components, faster.</p><p>For instance, when part geometry allows it, Montreal’s engineers are able to utilize detailed design features to degate the part during the ejection process (also known as in-die degating) allowing parts to then move to additional operations like tapping, wash and tumble, and other finishing processes without additional handling. Utilizing these advanced manufacturing technologies and Lean principles, Dynacast Montreal is able to increase reliability and quality while simultaneously minimizing downtime and part-to-part variance–engineering value into every stage of the die casting process for their customers.</p><h2>In-house capabilities</h2><p>With Techmire zinc multi-slide die casting platforms ranging from 7.9 - 65 tonnes, Dynacast Montreal is able to cast complex shapes while maintaining the perfect balance of machine tonnage versus machine speed to maximize the production output. This allows their customers to receive the best of both worlds – elite process capability and parts manufactured at high speed. And while this facility specializes in zinc die casting, Dynacast Montreal is equipped for just about every part of the die casting process.</p><p>Some of the Montreal’s features and capabilities include:</p><ul><li>20 Techmire zinc multi-slide machines</li><li>Precision tool building</li><li>Complex, high volume casting, including internal threads</li><li>Design, prototyping, and modeling services</li><li>Wide range of automated or semi-automated&nbsp;surface finishing&nbsp;including tumbling, polishing, and shot blasting</li><li>Wide range of secondary operations including tapping, reaming and drilling</li><li>Network of certified suppliers that can offer any cosmetic or protective coating required</li></ul><h3>Cast Internal Threads</h3><p>Over the years, Dynacast Montreal has leveraged intimate machine knowledge and tooling design expertise to cast internal threads. With a proprietary three-plate design, Montreal has the ability to cast reliable, easy starting internal threads every time. This means that their customers not only receive the benefit of the reduction of operations, but also the added benefit of the casting ‘skin’ on the threads which offers a significant increase in strength and durability. And with autodegating incorporated directly into the tooling, parts can go directly from the casting machine to shipping with no additional operations.</p><h3>Dynacast IP</h3><p>This facility is also largely responsible for the production of most of the<a href="/additional-capabilities/industrial-parts" target="_self">&nbsp;industrial products</a> for Dynacast IP. Dynacast Montreal has years of experience manufacturing a variety of commercial fasteners, including corrosion resistant wing nuts, smooth starting panel mounting nuts, and durable concrete anchors. </p><h2>Streamline your supply chain in-house</h2><p>Dynacast Montreal houses virtually every step of the die casting process. With the die cast machines, tooling production, casting and finishing services all in one place, you can single-source your entire project from their facility.</p><h2>All-in-one die casting with Dynacast Montreal</h2><p>With a comprehensive suite of die casting capabilities, Dynacast Montreal continues to develop innovative continuous flow manufacturing processes to provide the best service, state-of-the-art technology, and cost-effective solutions in industry.</p>

Die cast metal parts with a shiny surface finish

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Learn more about Dynacast's Montreal facility, offering innovative die casting solutions with a focus on high-quality production.

Dynacast Montreal Facility Spotlight | Die Casting

Dynacast Montreal's 44,000 square foot facility stands out for its innovative, high-volume die casting capabilities, featuring integrated in-house production from machine manufacturing to finishing, which enables precise, rapid, and reliable hardware solutions across multiple sectors.

Aerospace

Aerospace Leaders Choose Dynacast To Help Achieve Key Goals

Lightweighting

Complex, Precision Components

Repeatable Quality

Cost & Production Efficiency

Industry Leading Certifications

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Elevate Your Knowledge About Die Casting for Aerospace

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