Zinc alloys like Zamak 3, ZA-8, and custom blends offer exceptional strength-to-weight ratios, corrosion resistance, and cost efficiency for high-volume production. At Falcon CNC, we leverage 5-axis CNC technology and IATF 16949-certified processes to machine components such as automotive fasteners, surgical instrument housings, and robotic actuator gears. Our expertise spans die casting, precision milling, and surface finishing, ensuring compliance with ASTM B86 and ISO 13485 standards for critical industries.
Automotive: Zamak 5 alloy fasteners reduce vehicle weight by 15% while maintaining 380 MPa tensile strength, ideal for EV battery enclosures and transmission components.
Medical: Zinc-nickel plated surgical instrument housings comply with FDA hygiene standards, offering 99% bacterial resistance in sterilization cycles.
Robotics: ZA-8 alloy actuator gears achieve 1.5% elongation for high-cycle fatigue resistance in industrial automation systems.
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ISO 13485 Certified | 10-Day Lead Time | 15% Bulk Discounts
Zamak 3:
Applications: Consumer electronics casings, HVAC valves, and low-stress automotive brackets.
Benefits: 268 MPa tensile strength, 0.1% lead-free composition, and 40% lower cost than Zamak 5.
Zamak 5:
Applications: High-load automotive connectors, surgical tool hinges, and robotic joint components.
Benefits: 380 MPa strength with 1.3% elongation, enhanced by nickel plating for medical-grade corrosion resistance.
Technical Edge:
Die Casting Integration: Combines near-net-shape casting with CNC finishing to reduce material waste by 25%.
Surface Treatments: Electroless nickel plating (ASTM B733) for saltwater environments.
See how Falcon CNC’s zinc-nickel plated housings reduced bacterial adhesion by 40% for a global medical OEM. ISO 13485 certified, 0.01 mm tolerances, and 20% cost savings.
Client: Global Medical Device Manufacturer
Challenge: Stainless steel housings caused 15% weight penalties and frequent corrosion in autoclave cycles.
Solution:
Material: Zamak 5 alloy with electroless nickel plating (Ra 0.4µm).
5-Axis CNC Machining: Integrated snap-fit grooves (±0.01 mm) for tool assembly efficiency.
Results:
40% Lighter: Improved surgeon ergonomics during prolonged procedures.
Zero Corrosion: Passed 1,000-hour ASTM B117 salt spray testing.
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