Zamak Micro-injection:
for ultra-precise parts,
produced at high speed
ID Casting specializes in Zamak micro-injection molding using a multi-slider process—a niche technology that enables the mass production of complex micro-parts in very large quantities, with tight tolerances and unbeatable production costs.
The Process
What is Zamak microinjection?
Zamak micro-injection is a hot-chamber die-casting technique that uses multi-slide dies—with up to several perpendicular slides—which allow for the production of complex shapes that cannot be achieved through conventional die-casting.
Molten metal (zamak) is injected at high pressure into a closed mold. Solidification occurs almost instantly, which allows for very high hourly production rates while ensuring perfect reproducibility for each part.
This process is particularly well-suited for manufacturing micro-parts weighing 1 g to 30 g with complex internal or external geometries, undercuts, through-holes, or threads—without the need for routine secondary operations.
Unlike traditional two-cavity molding, the multi-slide system offers considerable design flexibility and significantly reduces the production cost of mass-produced parts.
Melting & Temperature Maintenance
Zamak is melted in a crucible built into the machine (hot chamber). Molding temperature: 400–425°C. The melt remains in the crucible at all times, reducing cycle times.
Closing the multi-slider tooling
The slides close simultaneously, forming the entire cavity with all its complex geometries—including undercuts and fine details.
High-Pressure Injection
The metal is injected under high pressure. The instantaneous filling ensures the density and dimensional accuracy of each part.
Automatic Solidification & Ejection
Rapid cooling, sequential opening of the slides, automatic ejection. Very short total cycle time, with identical repeatability.
Optional Finishes & Surface Treatments
Deburring, additional machining, and surface treatments (zinc plating, nickel plating, tin plating, etc.) are available in accordance with the specifications.
Why Choose This Process
The Benefits of Zamak Microinjection
A niche process that combines industrial performance, dimensional accuracy, and cost-effectiveness.
Complex Shapes & Tight Tolerances
The multi-slide system allows for geometries that are impossible to achieve with conventional molding: undercuts, through-holes, threads, and highly intricate raised details.
High production rate
Specialized automatic machines offer a very high hourly output. Ideal for very large-volume production runs with tight deadlines.
Reduced production costs
Compared to traditional processes (machining, sintering, plastics molding), Zamak micro-injection molding offers a significant reduction in unit cost even for medium-volume production runs.
Perfect reproducibility
Each part is identical to the previous one. Dimensional tolerances are guaranteed throughout the entire production run, with no drift over the course of the cycles.
Low energy consumption
Micro-injection machines use very little energy compared to conventional die-casting presses. This offers a tangible environmental and economic benefit.
Net-shape castings
The precision of the process often makes it possible to produce parts that are ready for use, without the need for costly secondary machining operations.
Alloys
Zamak 3 or Zamak 5: Which One Should You Choose?
ID Casting specializes in Zamak 3 and Zamak 5 for its micro-injection applications. Each alloy meets specific requirements.
| Property | Zamak 3 (ZA4G) | Zamak 5 (ZA4U1G) |
|---|---|---|
| Density | 6.6 g/cm³ | 6.7 g/cm³ |
| Molding temperature | 400–425 °C | 400–425 °C |
| Tensile Strength | 26–30 daN/mm² | 30–34 daN/mm² |
| Yield strength | 25–29 daN/mm² | 29–33 daN/mm² |
| Elongation | 3–6% | 2–5% |
| Compressive Strength | 41 daN/mm² | 60 daN/mm² |
| Fatigue Strength | 4.7 daN/mm² | 5.6 daN/mm² |
| Brinell Hardness | 80–90 HB | 85–95 HB |
| Copper (Cu) Content | < 0.03% | 0.7–1.1% |
| Requirement / Constraint | Recommended Alloy | Reason |
|---|---|---|
| High mechanical strength | Zamak 5 | Superior tensile, compressive, and fatigue strength |
| Slim connectors, decorative parts | Zamak 3 | Higher elongation, excellent castability |
| Parts Subject to Repeated Impacts | Zamak 5 | Increased Brinell hardness and fatigue resistance |
| Intricate details, thin walls | Zamak 3 | Optimal flow during injection molding |
| Surface Treatment (Electroplating) | Zamak 3 or 5 | Both alloys respond well to surface treatments |
| Standard / Designation | Zamak 3 | Zamak 5 |
|---|---|---|
| French Name | ZA4G | ZA4U1G |
| French Standard | NF EN 1774 | NF EN 1774 |
| Designation DIN 1743 | Zn Al4 (Z 400) | Zn Al4 Cu1 (Z 410) |
| RoHS Directive | Does not apply to Zamak-type zinc alloys | |
Areas of Application
Who uses our zamak micro-parts?
Zamak microinjection meets the requirements of many industrial sectors that demand precision, high volume, and competitiveness.
Available finishes
Surface Treatments on Zamak Micro-Parts
ID Casting offers or coordinates the main surface treatments to meet the aesthetic, functional, and anti-corrosion requirements of your parts.
Why ID Casting
French Expertise from a Specialist
Zamak micro-injection is a niche process that requires complete mastery of the machinery, tooling, and metallurgy. ID Casting has integrated this expertise directly into its group, with a dedicated facility in Dampierre-les-Bois (Doubs).
Unlike major international players, we offer direct contact with our technical teams, quick response times for mass-production launches, and genuine support throughout the co-design process.
- Technical expertise built up since SIMI's founding, now part of the ID Casting Group
- Production facility dedicated to zamak micro-injection molding (Dampierre-les-Bois, 25)
- In-house precision tooling: high-speed machining centers, EDM machines, grinding machines
- Certified first-melt zamak — guaranteed material traceability
- Technical support available starting in the design phase to optimize the part for the manufacturing process
- Quality certifications in effect throughout the ID Casting Group
- Capacity to deliver finished parts, including surface treatments
Frequently Asked Questions
Everything You Need to Know About Zamak Microinjection
Zamak micro-injection uses specialized automatic multi-slide machines designed for very small parts (1 to 30 g) with complex geometries. Conventional casting uses two-part molds, which are suitable for larger parts. Micro-injection enables much higher production rates and more intricate shapes on small components, with a highly competitive unit cost for high-volume production.
Zamak micro-injection is economically viable for medium-volume production runs. The cost of the tooling is recouped through the volume produced. For very high-volume production projects, this process offers the best value for money. Contact our sales team for a customized analysis based on your annual production schedule.
Yes, that is precisely one of the major advantages of the multi-slide process. The slides make it possible to create complex internal and external shapes—threads, holes, undercuts, and recesses—directly during casting, without the need for additional machining operations in most cases.
The RoHS Directive does not apply to Zamak-type zinc alloys. Furthermore, ID Casting uses only virgin Zamak certified by its suppliers, ensuring a controlled and consistent chemical composition across all production runs.
Tooling lead times depend on the geometric complexity of the part. Our in-house machinery (high-speed machining centers, EDM) allows us to keep lead times under control. Our engineering department is available from the design phase onward to optimize the part and reduce development time.
A project involving micro-parts made of zamak?
Talk to our engineers—get a quote within 48 hours and receive support right from the design phase.
