Precision die casting that delivers lightweight strength, tight tolerances, and repeatable quality for demanding defense applications.

United States army soldiers with firearms

Signicast_Industries_Defense.jpg

Defense

Speak to an Engineer

Large Square Card_Zinc.jpg

Die casting delivers lightweight metal components that maintain the strength and durability required for demanding defense applications, helping reduce overall system weight.

Lightweight Strength 

Large Square Card_Magnesium.jpg

High-precision die casting produces components with tight dimensional tolerances and consistent fit, supporting reliable performance across complex defense systems.

Precision & Tight Tolerances

Large Square Card_Aluminum.jpg

Controlled, repeatable manufacturing processes deliver consistent components from part to part that support quality requirements across production runs and long-term defense programs.

Repeatable Quality

Die casting enables complex geometries and integrated features that can help consolidate components, simplify assemblies, and reduce the need for secondary operations. 

Complex Geometries

Defense Leaders Choose Dynacast To Help Achieve Key Goals

Search All Certifications

Certification.png

Industry Leading Certifications

See All Resources

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?<h2>Castability</h2>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.<h2>Extended Die Life</h2>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<h2>Cycle Time</h2>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.Did you know that our proprietary multi-slide zinc die casting process can achieve upwards of 45 shots per minute?<h2>Mechanical Properties</h2>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.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.<table><tbody><tr><td>Material</td><td>Alloy</td><td>Yield Strength (0.2%)</td><td>Hardness</td></tr><tr><td>&nbsp;</td><td>&nbsp;</td><td>PSI X 10^3</td><td>Brinell (HB)</td></tr><tr><td>Zinc</td><td>Zamak 3</td><td>32</td><td>82</td></tr><tr><td>Zinc</td><td>EZAC</td><td>57</td><td>120</td></tr><tr><td>Aluminum</td><td>A380</td><td>23</td><td>80</td></tr><tr><td>Magnesium</td><td>AZ91D</td><td>23</td><td>63</td></tr></tbody></table>Try our interactive metal selector tool to compare physical and mechanical properties of other die cast alloys.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.   &nbsp;

Raw materials for the die casting process

Dynacast_Resources_Raw Material

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

<h3>Precise . Efficient . Versatile</h3>We have produced billions of <a href="/metals/zinc" target="_self">zinc die cast components</a>—from one hundredth of a gram to one kilogram in size. With the help of our engineering team, our customers realize the full potential of engineering with zinc!&nbsp;&nbsp;Fill out the form to access our webinar and discover how zinc can help you achieve:<ul><li>Design freedom </li><li>Reduced assembly</li><li>Tighter tolerances</li><li>Faster cycles times</li><li>Reduced cost</li><li>Longer tool life</li><li>Enhanced surface finishing</li><li>And more!</li></ul>&nbsp;

Blocks of zinc metal to be used in die casting

Dynacast_Resources_Zinc Blocks

Discover key design considerations and benefits of using zinc for your die casting projects in this expert-led webinar.

Zinc Die Casting Design Tips | Dynacast

Discover how to leverage zinc die casting to achieve design freedom, reduced costs, and enhanced performance with insights from our engineering team—access the webinar now! 

Designing in Zinc

<h2>What Drives Tool Cost? Understanding Die Cast Tooling Efficiency</h2>Tooling is one of the most critical — and costly — elements in the die casting process. In this one-hour on-demand webinar, Dynacast’s tooling experts break down the factors that influence <a href="/additional-capabilities/tooling" target="_self">die cast tooling</a> costs and share proven strategies to maximize tool performance and lifespan.You’ll learn how to:<ul><li>Identify and manage the key cost drivers behind die cast tooling</li><li>Balance design complexity with production efficiency for better ROI</li><li>Extend tool life through smarter material selection and maintenance</li><li>Improve quality, consistency, and cost-effectiveness across every production run</li></ul>Whether you’re designing a new tool or managing an existing one, this webinar will help you make informed, cost-efficient tooling decisions that reduce downtime and improve production output.Watch now to gain expert insights that can help you optimize your tooling investment and enhance your overall precision manufacturing performance.

Dynacast_Resources_Die Casting Mold

Watch our on-demand webinar to learn the key die casting tooling cost factors, including design complexity, materials, production volume, and manufacturing requirements.

Die Casting Tooling Costs: Expert Webinar | Dynacast

Discover the key factors that impact the cost of die cast tooling and learn strategies to maximize tool life in this insightful hour-long webinar. 

Defense

Defense Leaders Choose Dynacast To Help Achieve Key Goals

Lightweight Strength

Precision & Tight Tolerances

Repeatable Quality

Complex Geometries

Industry Leading Certifications

BEYOND THE BASICS

Elevate Your Knowledge About Die Casting for Defense

Article

Webinar

Webinar

Interested in starting your die casting journey?