Aluminium vs Zinc Die Casting: Which Alloy Should You Use?

Aluminium and zinc are the two most common alloys used in high-pressure die casting (HPDC)—but they serve very different purposes. Choosing the right one affects part weight, strength, finish, cost, and long-term performance.

Here’s a practical breakdown of how they compare:

⚙️ Aluminium Die Casting (e.g. ADC12, A380)

Pros:

• High strength-to-weight ratio

• Good thermal and electrical conductivity

• Corrosion resistant

• Ideal for structural or heat-sensitive parts

Best For: Power tool housings, brackets, electronics enclosures, EV parts, lighting components

Considerations:

• Higher injection pressures required

• Requires higher die temperature

• Less fluid than zinc → larger wall thickness preferred

⚙️ Zinc Die Casting (e.g. Zamak 3, Zamak 5)

Pros:

• Excellent fluidity for complex/thin features

• Lower melting point = longer tool life

• High dimensional accuracy (tight tolerances)

• Smooth surface finish (less post-processing)

Best For: Consumer product housings, small gears, EMI/RF shielding parts

Considerations:

• Heavier than aluminium

• More suitable for smaller parts (typically <500g)

• More expensive than aluminium by ~50%

At LVIO Precision, we support both zinc and aluminium HPDC across machine sizes from 135T to 650T. We’ll work with you to validate your selected alloy based on your part’s geometry, required properties, and downstream operations like machining or finishing.