ID Casting & The Automotive Industry

Zamak: A Precision Partner for the Automotive Industry

Zamak (a zinc-aluminum alloy) is a go-to material for manufacturing technical automotive parts via die casting. Its fluidity in the molten state allows for the production of complex geometries and tight dimensional tolerances, without the need for additional machining in most cases. This is a decisive advantage for components such as locks, door handles, seat mechanisms, headlight brackets, and dashboard elements, where repeatability and surface finish are essential.

Thanks to its high mechanical strength, good thermal conductivity, and compatibility with surface treatments (chromium plating, painting, anti-corrosion coatings), Zamak meets the requirements of automotive manufacturers and suppliers, both for structural parts and for components subjected to vibrational or thermal stresses.

At ID Casting, our expertise in Zamak is supported by several dedicated production sites—including the micro-injection facility in Dampierre-les-Bois for very small parts—ensuring responsiveness, consistent quality, and process control, from design through mass production.

Magnesium (AZ91D) Injection Molding

Magnesium is a very lightweight material—about 30% lighter than aluminum—making it an excellent choice for reducing vehicle weight and increasing range, particularly in electric cars. It effectively absorbs vibrations, which is a real advantage for components related to comfort and safety. Despite its light weight, it is strong and allows for the production of thin, uniform parts suited to automotive production rates. Another advantage is a guaranteed tool life of approximately 400,000 injections, ensuring long-term reliability and cost-effectiveness for high-volume automotive projects.

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Zamak Micro-Injection in the Automotive Industry

Micro-injection molding is used to manufacture very small, high-precision automotive parts, such as connectors, sensors, and small screws. The result is a thin, clean, and ready-to-use part that requires no further finishing. This process is ideally suited for high-volume production, with very little material waste, making it both a cost-effective and reliable solution for the automotive industry.

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Zamak Injection Molding

Zamak is a strong, easily moldable material, ideal for everyday automotive parts such as locks, door handles, and headlight brackets. It allows for the production of complex shapes in a single step, with a high-quality finish that can be painted or chrome-plated. Its density of 6.7 g/cm³ ensures compact and durable parts, while the precision of the injection molding process guarantees tight tolerances, part after part, even in high-volume production. Zamak also offers a guaranteed mold life of approximately 1,000,000 injections, a major advantage for the profitability of automotive projects. Another significant advantage: technical parts made of Zamak are 100% recyclable, a real plus for manufacturers committed to environmental sustainability.

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Our Automotive Applications

  • Armrests
  • Airbag
  • Antenna
  • Horn
  • Roof rack
  • Seat Belt
  • Counter
  • Heavy-Duty Brake Assembly
  • Valve and Distributor Bodies
  • Pump cover
  • Dashboard Elements
  • Seat mechanism
  • Door handle
  • Windshield wiper arm pivot
  • Pompes
  • Fittings
  • Rearview Mirror
  • Lock
  • Headlight bracket
  • Monitor Stand
  • Remote Control