Zamak 3 (Zinc Die Cast) vs A380
Zamak 3 zinc and A380 aluminum are the two workhorse die-casting alloys, chosen by very different priorities. Zamak 3 melts at low temperature, fills the finest detail, extends tooling life, and plates beautifully — ideal for decorative and precision die castings. A380 is far lighter, runs hotter, and offers better strength-to-weight for structural housings. Density drives much of the tradeoff: zinc is ~6.6 g/cm3 versus aluminum's ~2.71.
The verdict
Choose Zamak 3 for fine detail, thin features, plated finishes, and long tooling life in smaller die-cast parts. Choose A380 aluminum when weight, higher service temperature, and strength-per-weight matter for structural housings. Zinc wins on detail and tooling economy; aluminum wins on weight and thermal capability.
Side-by-side data
| Property | Zamak 3 (Zinc Die Cast) | A380 |
|---|---|---|
| Category | Zinc Alloy | Aluminum |
| Density (g/cm³) | 6.6 | 2.71 |
| Tensile strength (MPa) | 268 | 324 |
| Yield strength (MPa) | 208 | 159 |
| Elongation (%) | 10 | 3 |
| Hardness | 82 HB | 80 HB |
| Max service temp (°C) | 90 | 170 |
| Machinability | ●●●●● | ●●●●● |
| Corrosion resistance | ●●●●● | ●●●●● |
| Relative cost | ●●●●● | ●●●●● |
| Thermal cond. (W/m·K) | 113 | 96 |
| Typically used for | Detailed plated die castings | High-volume die-cast housings |
Which should you choose?
Choose Zamak 3 (Zinc Die Cast) when…
- You need the finest detail and thinnest features — zinc's low melt fills intricate cavities crisply
- Plating and decorative finishes matter; zinc accepts chrome, nickel, and paint extremely well
- Long tooling life is valued — low casting temperature is gentle on dies versus aluminum
- Tight as-cast dimensional precision reduces secondary machining
- Part size is small to medium where the ~6.6 g/cm3 density penalty is acceptable
- Lowest tooling and per-part cost on small detailed castings (Zamak ~1.8/5 cost)
Choose A380 Aluminum when…
- Weight matters — A380 is ~2.71 g/cm3, less than half zinc's ~6.6
- You need better strength-to-weight for structural housings and brackets
- Service temperature runs higher — A380 lists ~170 C vs Zamak's ~90 C
- Higher absolute tensile helps — ~324 MPa vs Zamak's ~268 MPa (nominal as-cast)
- Large, lightweight high-volume housings are the target
- You want a low material cost (~1.8/5) with far better thermal and weight performance
Key differences that matter
- Zinc is much denser (~6.6 vs ~2.71 g/cm3) — A380 castings weigh less than half as much
- Zamak's low melt temperature yields finer detail, thinner walls, and longer die life
- Zinc plates and finishes superbly, making Zamak the choice for decorative hardware
- A380 tolerates more heat (~170 C vs ~90 C max service)
- A380 has higher as-cast tensile (~324 vs ~268 MPa) and better strength-to-weight
- Material costs are similar (~1.8/5 each); zinc's tooling longevity can lower amortized cost
- Choice splits cleanly: zinc for detail/finish/tooling, aluminum for weight/temperature/structure
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Open the Material SelectorGet a Quote →Frequently asked questions
Why does Zamak 3 produce finer detail than aluminum?
Zinc's much lower casting temperature lets it fill thin walls and intricate cavities cleanly without the thermal shock and shrinkage issues aluminum faces. The lower melt is also gentler on the die, so Zamak tooling lasts far longer. This combination makes zinc the go-to for small, detailed, precision die castings and decorative hardware.
Which is lighter, Zamak 3 or A380?
A380 aluminum, by a large margin. At ~2.71 g/cm3 it weighs less than half as much as Zamak 3 at ~6.6 g/cm3. For any weight-sensitive housing, bracket, or portable product, aluminum is the clear choice. Zinc's density is the main penalty you accept in exchange for its detail and finishing advantages.
Which handles heat better?
A380 aluminum. This dataset lists its service near 170 C versus Zamak 3 around 90 C. Zinc alloys soften and creep at relatively modest temperatures, so for under-hood, motor-adjacent, or hot-environment parts, aluminum is required. Keep Zamak to near-ambient service where its detail and plating strengths pay off.
Does zinc die casting save on tooling cost?
Often yes, over the tool's life. The low casting temperature greatly reduces thermal wear on the die, so Zamak tooling typically lasts longer than aluminum die-cast tooling. On high-volume detailed parts that longevity can lower the amortized cost per piece, even though raw material costs for the two alloys are similar (~1.8/5 each).
Which is stronger?
On absolute as-cast tensile, A380 is slightly higher (~324 vs ~268 MPa nominal), and it has a clear strength-to-weight advantage given its much lower density. Zamak 3 is respectably strong for small detailed parts but is not a structural lightweight. For load-bearing housings, aluminum's strength-per-weight makes it the better structural casting.
Property values are typical/nominal figures for early-stage guidance only and vary by temper, grade, supplier and heat treatment. Confirm critical specifications against a certified datasheet or with an mfgiq engineer before production.