Automotive Accessories
Emblem plates, badge frames, interior trim bezels, mirror housings, decorative end-caps. Zamak 5 carries the load; Zamak 3 carries the plated decorative work.
20+ years of mold engineering · Dongguan, China
Custom Zinc & Zamak Die Casting Services in China
From Zamak tooling to chrome-plated production parts — single-source accountability backed by 20+ years of mold engineering experience.
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Tight tolerances down to ±0.05 mm — sharp enough for lock cylinders & chrome trim
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Hot chamber cycles 30–45s — 3× faster than aluminum, scales to 1M+ shots
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The most plate-friendly die cast alloy — chrome, nickel, gold without primer
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Full Zamak family in-house — Zamak 3 / 5 / 2 / 7 / ZA-8 specified in writing
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One team — tooling → casting → plating → CMM — single PO, single owner
Module 02 — Scope
What You Get From KTM — Zinc Die Casting Scope
Before you brief our engineers, here's the full scope.
01
Tooling
Zamak molds built in-house in Dongguan on Sodick EDM and Fanuc CNC. Trial, Standard, and Premium (H13 / 2344) tiers.
02
Hot Chamber Production
Engineered by KTM through qualified casting partners under our QC. Zamak 3 through ZA-8.
03
Plating & Finishing
Chrome, nickel, gold, black chrome, powder coating, polishing — one invoice, RAL / Pantone matchable.
04
QC
In-house metrology lab. DFM, Casting Simulation, CMM, and material certificate on every shipment.
Of these four, alloy selection moves the project most — and it's where most zinc die casting programs quietly fail.
See which Zamak grade fits your projectModule 03 — Alloys
Full Zamak Family Specialty — Zamak 3, 5, 2, 7 & ZA-8
Alloy selection is where most zinc die casting projects quietly succeed or fail. Zamak 3 is the default across the industry — and for most projects, the right call. But when plating yield, load capacity, or long-term dimensional stability are on the line, the other four grades earn their place. KTM specifies the grade in writing before any tooling quotation.
| Grade | Composition | Tensile (MPa) | Hardness (HB) | Density (g/cm³) | Best For |
|---|---|---|---|---|---|
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Zamak 3Most used
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Zn + ~4% Al + trace Mg | 283 | 82 | 6.6 | Plated decorative hardware, lock cylinders, zipper pulls, electronics housings |
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Zamak 5
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Zn + ~4% Al + ~1% Cu | 328 | 91 | 6.6 | Structural hardware, automotive accessories, gears, load-bearing fittings |
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Zamak 2
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Zn + ~4% Al + ~3% Cu | 359 | 98 | 6.6 | Heavy-duty tooling, bushings, high-strength fittings |
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Zamak 7
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Zn + ~4% Al + Ni · ultra-low impurities | 283 | 80 | 6.6 | Premium chrome-plated parts, faucet trim, luxury hardware |
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ZA-8
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Zn + ~8% Al + ~1% Cu | 374 | 103 | 6.3 | Aluminum-alternative bearings, weight-sensitive industrial parts |
Engineering Notes
What the spec sheet won't tell you.
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Zamak 3
Runs ~70% of all zinc die casting projects worldwide. The grade KTM ships in highest volume to European hardware and furniture customers.
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Zamak 5
Gains ~15% tensile strength over Zamak 3 from 1% copper — at a small cost in elongation. Routine across KTM's lock programs.
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Zamak 2
Carries a known trade-off: higher copper introduces long-term dimensional drift. Not recommended for parts requiring 10+ year precision stability.
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Zamak 7
Delivers the cleanest substrate for chrome plating. Specify when blistering, pitting, or orange peel have cost you a scrap batch before.
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ZA-8
The only ZA-family alloy compatible with hot chamber die casting. The right answer when weighing aluminum but the part sits under 1 kg.
Which Zamak Grade for Your Project?
Plated decorative part→ Zamak 3
Structural load→ Zamak 5
Maximum hardness→ Zamak 2
Premium chrome plating→ Zamak 7
Aluminum-alternative under 1 kg→ ZA-8
Undecided? Send your drawing and target application — KTM's engineering team recommends the grade in writing, with rationale, before any tooling quotation.
Request a written recommendationModule 04 — Hot Chamber Process
How KTM Runs the Hot Chamber Process
With the Zamak grade locked, here's how KTM builds your zinc parts — and where a mold-maker's eye saves weeks of T1 rework. Hot chamber submerges the injection mechanism in the molten zinc pool: shorter cycles, mold life reaching 1,000,000+ shots, and consistent dimensional repeatability.
1M+
shots / mold
±0.05
mm tolerance
30–45s
cycle time
Mold Life & Tool Steel — Pick the Tier That Fits
Trial / Prototype
Small batches
shots
P20 or pre-hardened
Design validation
Standard Production
200,000 – 500,000
shots
H13 / SKD61 / 8407 / 8418 (HRC 48–52)
Most KTM zinc programs
Premium
1,000,000+
shots
LG / W360 / TS580 / YXR33 (HRC 54–60)
High-gloss, long-life, anti-soldering
Design Guidelines & Tolerances
Standard Tolerance
±0.1 – ±0.2 mm
High-Precision
±0.05 mm on request · ±0.02 mm w/ CNC post
Minimum Wall
0.5 mm
Recommended Wall
1.0 – 3.0 mm
Draft Angle
1°–3° outer / 2°–5° inner
Surface Roughness
Ra 0.8 μm (mirror-polishable)
Max Part Weight
up to ~5 kg (typical 10 g – 2 kg)
Cycle Time
30–45 s (60+ s for complex)
Minimum Radius
0.5 mm
Upload CAD · Response within 24–72h
Module 05 — Surface Finishing
Plating & Surface Finish on Zamak — one invoice, one owner
Hot chamber casting gives you geometry. Plating gives your Zamak part its final identity. KTM coordinates every finish through audited partners operating under KTM's QC standards — documented pre-treatment QC prevents blistering, pinholes, and adhesion failures.
01
Electroplating
The reason you chose Zamak
- Chrome (bright & satin)
- Nickel (electroless, bright, matte)
- Gold (jewelry-grade)
- Black chrome
02
Painting & Coating
RAL / Pantone matchable
- Powder coating
- Wet paint (solvent / water-based)
- E-coat (ED coating)
03
Mechanical Finishing
Class-A cosmetic surfaces
- Polishing (Ra 0.2 μm)
- Sandblasting
- Brushed satin
- Vibratory tumbling
04
Chemical Treatment
Corrosion & adhesion
- Passivation
- Chromate conversion (yellow/olive/clear)
- Phosphating
Color matching without guesswork.
Send a physical sample, RAL reference, or Pantone code with your RFQ. For mixed-finish assemblies — bright chrome body with a satin nickel accent, or powder-coated base with a polished bezel — KTM sequences plating steps and masking before quoting, so the invoice matches the drawing.
Module 06 — Industries
Where KTM Zinc & Zamak Parts actually ship
Not catalog renders — these leave our dock weekly. KTM's strongest zinc die casting references sit in three sectors below.
Hardware & Locks
Lock cylinders, padlock bodies, door handles, zipper pulls, belt buckles, furniture trim. Where Zamak 3's plating affinity and ±0.05 mm repeatability matter most.
Consumer Electronics
Connector housings, USB shells, EMI shielding frames, device mounts, decorative end-caps. Thin walls, tight tolerances, chrome or satin nickel plating.
Applications we also support: Cabinet handles, faucet trim, lamp bases, bushings, valve bodies, machinery fittings, instrument enclosures — alloy and finish matched to load, environment, and program volume.
Module 07 — Quality Control
Documented reports before every shipment
Every zinc die casting shipment leaves KTM with three reports your QA team can file directly: a DFM analysis from the design stage, a Casting Simulation review for complex parts, and a detailed ISIR dimensional report.
DFM Analysis
Casting Simulation (Moldflow)
ISIR Dimensional Report (CMM)
Material Certificate per Shipment
Plated parts are inspected twice — once after casting, again after plating. A defect caught at the casting stage never reaches the plating tank, and a plating defect never reaches your dock.
Module 08 — How to Start
The 7-Step Path from RFQ to Shipment
One project lead, one engineering channel, one written quote — from the moment your CAD lands in our inbox to the day your parts ship. NDA signed first on request.
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Step 101 / 07
RFQ & Structural DFM
Day 0–3Send STEP / IGES / STP / DWG with your project specs. Written quote returned within 24–72h.
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Step 202 / 07
Detailed DFM & Casting Simulation
After orderWall thickness, draft, parting, gate location. Moldflow runs only when geometry is complex.
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Step 303 / 07
Tooling at Dongguan
6–10 weeksMold steel matched to program life. Fanuc CNC + Sodick mirror EDM. Weekly progress reports.
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Step 404 / 07
T1 Trial Shots
—First samples shipped for dimensional and cosmetic sign-off. Adjustments documented in writing.
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Step 505 / 07
Production or Mold Export
—If KTM runs production, volume is engineered by our partners under our QC.
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Step 606 / 07
Finishing & QC
—Chrome, nickel, gold, powder. ISIR before shipment.
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Step 707 / 07
Pack & Ship
—Export paperwork handled. Single PO, single owner.
Module 09 — Why KTM
A zinc die casting manufacturer built to own your whole program
Seven steps need an owner. KTM is built to be that owner — founded and technically led by a mold-design specialist with 20+ years of hands-on factory experience. The six reasons below are why EU and North American brands keep returning.
01
One Contract, One Engineering Owner
Tool, production, and finish run under one PO, one engineering contact, one timeline. From RFQ to chrome-plated shipment, accountability never transfers — the same engineer who reviewed your DFM signs off your final QC report.
02
A Mold-Maker's Eye on a Casting Problem
A mold-design founder learns to prevent casting defects before steel is cut, not fix them after T1. That shows up in gate placement, vent layout, and parting lines that respect plating geometry — the decisions that determine whether your part clears the chrome tank on the first batch.
03
Alloy Matched in Writing
KTM commits to the full Zamak family because the founder's mold-engineering background reads each grade as a distinct engineering call, not a quoting default.
04
Defect Ownership Stays Inside KTM
With finishing coordinated under KTM's QC, a porosity or adhesion issue does not turn into a vendor dispute. Parts are inspected at the casting stage and again after plating, and any rework decision sits with KTM's engineering team — documented, dated, owned.
05
Engineers on Email
Daily updates run through fast English communication. Complex technical questions — porosity diagnosis, draft revision, plating sequencing — escalate to the engineering team within 24 hours, with answers grounded in mold-shop reality.
06
China Cost Structure, European Engineering Discipline
Reshoring buys you a domestic time zone. It does not buy you a mold built faster, documented better, or coordinated with fewer vendors. KTM applies the documentation discipline EU Tier-1 brands expect — DFM before tooling, ISO 9001:2015 QMS, full inspection — at a cost structure splitting work across three domestic suppliers cannot match.
The engineering DNA explains why the seven steps hold. What it actually costs you — line by line, with no surprise invoices halfway through tooling — is the next conversation.
↓ See How KTM Quotes Zinc Die Casting ProjectsModule 10 — Pricing Framework
What actually drives your zinc die casting cost
Transparent pricing starts by showing you the levers — not hiding them behind a single line item. Every zinc die casting quote from KTM is built from the same six drivers, listed in the order they move the number.
01Tooling Complexity
Cavity count, slide and lifter count, mold size, and steel grade set the baseline. A single-cavity trial tool and a four-cavity Premium tool sit on very different cost curves — we recommend the right tier in writing, never the most expensive by default.
02Zamak Grade
Zamak 3 is the reference price. Zamak 7 and ZA-8 carry a modest premium tied to alloy purity. Grade choice also shifts scrap rate and plating yield, both of which flow back into per-part cost.
03Part Geometry & Shot Weight
Wall thickness, undercuts, deep cores, and finished weight drive cycle time and zinc consumption. Two parts with identical bounding boxes can quote 20–30% apart on geometry alone.
04Surface Finishing Stack
A raw-cast part and a bright-chrome part with masked satin accents are not the same invoice. Each plating, coating, or mechanical step is a documented line — quoted before steel is cut.
05Order Quantity & Release Schedule
No MOQ. Annual blanket releases against one tool typically land 15–25% below one-off batches of the same quantity.
06Casting Simulation — On Request
For complex geometry or tight cosmetic zones, Moldflow can be run post-order at the customer's request. Standard parts skip it. We don't bill analysis your part doesn't need.
Quote Locked once confirmed
As long as drawings and specifications remain unchanged, the price you accepted is the price you'll be invoiced — tooling, production, QC documentation, packaging, and export paperwork included. Any change order is quoted in writing before we proceed.
Cost questions surface the same way technical ones do — in a list. Below are the thirteen engineers and sourcing managers ask most. ↓
Module 11 — FAQ
Frequently Asked Questions
Cost questions surface the same way technical ones do — in a list. The thirteen we hear most:
1. What's the difference between Zamak 3 and Zamak 5?
Zamak 3 is the default for plated decorative work — best castability and chrome adhesion. Zamak 5 adds ~1% copper for ~10% higher tensile strength, suited to load-bearing parts.
2. Can zinc die castings be chrome plated?
Yes. Zamak 3 and Zamak 7 are among the most chrome-friendly die cast alloys. KTM documents pre-treatment QC on every plated batch.
3. What is hot chamber die casting?
The injection mechanism sits in the molten zinc pool — short cycles, long mold life, the right fit for Zamak. Cold chamber is reserved for aluminum.
4. How long do zinc die casting molds last?
Trial molds cover validation. Standard H13/2344 tooling reaches 200,000–500,000 shots. Premium with maintenance exceeds 1,000,000.
5. When should I choose zinc over aluminum?
Zamak for parts under ~1 kg needing tight tolerances or chrome plating; aluminum for larger or thermally loaded parts — see our aluminum die casting services.
6. Do you run Moldflow on every project?
No. Casting Simulation runs only on client request, after order confirmation, for complex parts or tight cosmetic zones — never as a surprise charge.
7. Can KTM handle both tooling and production?
Yes. Tooling built in-house in Dongguan; production engineered by KTM's team through qualified hot chamber partners under our QC standards.
8. What surface finishes do you offer for Zamak?
Chrome, nickel, gold, black chrome, powder coating, wet paint, E-coat, polishing, sandblasting, passivation — one invoice, RAL and Pantone matchable.
9. What is your MOQ?
None strict. Smaller runs pair with a trial mold at higher unit cost; production tooling unlocks lower per-part pricing as volume justifies.
10. What is your lead time?
Tooling 6–10 weeks depending on cavity count, steel grade, and slide complexity. First batch follows T1 sign-off. Progress reports at five milestones.
11. Do you sign NDAs before reviewing drawings?
Yes. Check the NDA box on the RFQ form — signed before any CAD is opened. Files stored encrypted, need-to-know access.
12. Why source zinc die casting from China rather than reshoring to USA or Europe?
Two structural realities. Dongguan's die casting cluster keeps tooling, casting, plating, and finishing within a 50 km radius — compressing lead times that fragmented Western vendors can't match against three separate domestic suppliers. Combined with mature cost structure and European-standard documentation, single-source accountability lands faster from China than from a reshored chain.
13. Zamak die casting in China vs. reshoring to US or Europe — what's the real cost gap?
For Zamak parts under 1 kg with chrome plating, KTM lands 30–45% below Europe tooling cost and 40–55% below US, with comparable lead times once the Dongguan cluster's tool-cast-plate-pack chain is factored in. The gap closes for parts above 5 kg or programs requiring weekly EU delivery — for those, we'll tell you honestly that nearshoring may win.
Twelve answers down. The thirteenth — what your Zamak part costs and when it can ship — lands in your inbox after the RFQ. ↓
Module 12 — Final CTA
Ready to Start Your Zinc Die Casting Project?
Upload your STEP, IGES, or DWG files. Within 24–72h, our engineering team returns a written quote covering tooling, hot chamber production, plating, QC documentation, and export paperwork — locked on your unchanged specs.
One partner from Zamak tool to chrome-plated production part.
NDA First
Quote Locked
Weekly Progress Reports
Engineering-Led Quality Resolution