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Zinc Machining Services by TOPS Precision

  • Fast & Accurate Machining – Achieve ±0.01 mm tolerances with cycle times up to 30% faster than industry norms, optimized for zinc parts.

  • High-Quality Finishes – Corrosion resistance over 500 hours (ASTM B117) with optional plating or coatings from 5–25 µm.

  • Alloy Flexibility – Expertly machine all Zamak and ZA alloys, supporting parts from 1g to 5kg with excellent strength and castability.

  • Full-Service Support – DFM in 48 hours, mold lead times from 20 days, and 98% on-time delivery for end-to-end project success.

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    TOPS Precision specializes in high-performance zinc machining, combining advanced multi-axis CNC technology with skilled engineering to deliver strong, detailed, and efficient components. We serve the automotive, electronics, HVAC, and consumer product sectors with precision parts held to tolerances as tight as ±0.01 mm.

    From low-volume prototypes to high-volume production, we ensure high quality, fast turnaround, and tight tolerances. As a one-stop zinc machining partner, we handle everything—from material selection and tooling to machining, finishing, and final inspection—streamlining your supply chain and accelerating your time to market.

    What are Zinc and Its Alloys?

    Zinc is a highly corrosion-resistant, bluish-white metal prized for its exceptional formability, recyclability, and cost-effectiveness. While pure zinc (typically ochre or gray) sees limited practical use, TOPS Precision expertly enhances its performance by alloying it with aluminum, copper, or magnesium, creating high-quality Zamak and ZA alloys. These advanced alloys are valued for their superior mechanical strength, excellent wear resistance, and versatile machinability, making them ideal for precision casting and high-accuracy machining applications across diverse industries.

    What Is Zinc Machining?

    Machining zinc alloys involves specialized CNC processes such as milling, turning, drilling, tapping, and finishing. While zinc’s inherent softness and ductility make machining straightforward, achieving exceptional quality demands precise control to avoid common issues like burr formation, material deformation, or tool buildup.

    At TOPS Precision, we leverage advanced CAD/CAM modeling and high-speed CNC machining centers specifically optimized for soft-metal machining. Our experienced engineers select premium-grade carbide cutting tools, meticulously calculated speeds and feeds, and high-quality lubricants to ensure clean cuts, minimal tool wear, and unmatched precision—guaranteeing consistent, superior results for every project.

    What Is Zinc Machining?

    How Zinc Machining Works?

    Zinc machining involves shaping zinc or zinc alloy components using high-precision tools, typically through advanced CNC (Computer Numerical Control) processes. Thanks to zinc’s excellent machinability, operations such as cutting, drilling, milling, turning, and tapping can be performed at high speeds with minimal tool wear. At TOPS Precision, we utilize state-of-the-art CAD software to generate detailed part designs, which are then translated into precise tool paths—ensuring every cut meets strict dimensional and performance specifications.

    Our high-performance CNC lathes and mills are configured to machine zinc billets or die castings layer by layer, achieving tight tolerances and consistently smooth surface finishes. While zinc dissipates heat moderately during machining, we apply lubricants and coolants selectively to maintain optimal thermal conditions. To prevent burrs or deformation, we rely on high feed rates, razor-sharp carbide tools, and rigid fixturing. Post-machining, components undergo professional deburring, polishing, and optional surface coatings—enhancing both durability and cosmetic appeal to meet the highest industry standards.

    Properties of Zinc

    Here are some of the properties of zinc:

    Properties of Zinc?

    1. Excellent Machinability

      Zinc alloys are among the most machinable metals, typically rated above 90% machinability. At TOPS Precision, we leverage this advantage using high-speed CNC equipment to achieve faster cutting, longer tool life, and highly efficient large-scale production. This makes zinc ideal for high-volume, cost-effective machining projects.

    2. Corrosion Resistance

      Zinc naturally forms a protective zinc oxide layer, which resists oxidation and corrosion. Our zinc components are engineered for durability in harsh environments, including automotive, outdoor, and industrial applications—where long-lasting performance is critical.

    3. Low Melting Point

      With a melting point of 419.5°C (787°F), zinc is ideal for casting and thermal processing. At TOPS, we optimize this property to enable easy mold filling, lower energy consumption, and efficient integration with high-precision die casting workflows.

    4. Dimensional Stability

      Zinc alloys exhibit minimal shrinkage and excellent thermal stability, allowing our team to machine parts to tight tolerances with high repeatability. This makes our zinc components suitable for precision applications where dimensional accuracy and long-term stability are essential.

    5. Good Strength and Toughness

      Zinc alloys offer a reliable balance of strength and ductility. We specialize in machining high-performance grades like ZA-12 and ZA-27, enabling structural parts with enhanced mechanical properties for both light-duty and demanding load-bearing applications.

    6. Electrical Conductivity

      Zinc’s moderate electrical conductivity makes it suitable for components such as electrical housings and terminals. At TOPS, we machine zinc parts that perform well where conductivity and corrosion resistance must coexist, especially in electrical and electronics sectors.

    7. High Density

      With a density of around 6.6 g/cm³, zinc gives components a solid, premium feel. This makes it perfect for machined products like luxury handles, fixtures, and consumer goods, where weight and substance enhance the perception of quality.

    8. Recyclability

      Zinc is 100% recyclable without any loss in performance. Our machining operations prioritize sustainable practices, allowing us to recycle and reuse zinc materials efficiently—providing clients with economical and environmentally responsible solutions.

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      Types of Zinc Alloys for Machining

      The following are different types of zinc alloys along with their properties:

      Alloy

      Composition

      Key Properties

      Best Applications

      Zamak 3

      Zn + ~4% Al

      Most commonly used; excellent surface finish

      Consumer electronics, housing

      Zamak 5

      Zn + ~4% Al + 1% Cu

      Higher strength;,more wear-resistant

      Gears, locks, fittings

      Zamak 7

      Zn + Al + low Mg

      Better casting flow, great for small details

      Connectors, intricate components

      ZA-8

      Zn + ~8% Al

      Stronger; impact-resistant; easily machined

      Brackets, handles, hardware

      ZA-12/ZA-27

      Zn + 12–27% Al

      Very high strength; used for structural parts

      Bushings, bearings, and high-load mechanisms

      Different Zinc Machining Processes

      The following are some of the main machining processes that we can provide on zinc:

      1. CNC Milling

        Ideal for 2D and 3D zinc components such as enclosures, housings, and mounting plates. At TOPS Precision, we utilize advanced multi-axis CNC milling to achieve complex contours with high dimensional accuracy and repeatability—perfect for both prototyping and mass production.

      2. CNC Turning

        Best suited for cylindrical zinc parts like shafts, bushings, and pins. Our high-precision CNC lathes ensure exceptional concentricity, fine surface finishes, and fast cycle times, making us a trusted partner for tight-tolerance round components.

      3. Tapping and Drilling

        We deliver clean, accurately machined holes and threads for fasteners, connectors, or pressure-tight systems. With automated tapping heads and optimized drill parameters, we ensure high consistency and structural integrity in every part.

      4. Reaming and Boring

        Used to fine-tune hole diameters and ensure perfect alignment in mechanical assemblies. Our precision reaming and boring processes help eliminate tolerance stack-up, allowing for seamless part fitment in critical applications.

      5. Deburring

        Our meticulous deburring processes remove sharp edges, chips, and machining residues to improve component functionality, safety, and aesthetic appeal—all while maintaining tolerance integrity.

      6. Engraving and Profiling

        Whether it’s part numbers, serial codes, or branding, our high-accuracy CNC engraving ensures durable, legible markings directly onto zinc surfaces—ideal for traceability, identification, and product authentication.

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        Choosing the Correct Zinc Alloy to Machine

        The selection of zinc alloy is important in terms of the performance of their parts and cost-effectiveness:

        Choosing the Correct Zinc Alloy to Machine

        • Zamak 3 – Best suited for cosmetic parts, tight-tolerance components, and high-quality die casting, offering excellent surface finish and dimensional stability.

        • Zamak 5 – Ideal for structural components or load-bearing parts, providing enhanced strength and hardness for demanding mechanical applications.

        • Zamak 7 – Recommended for fine-walled or intricate parts, offering superior fluidity and castability for highly detailed geometries.

        • ZA-8 – A great choice for medium-load or high-impact applications, combining strength with excellent machinability.

        • ZA-12 / ZA-27 – Engineered for high-stress, heavy-wear parts that require consistent performance and repeated flexibility under load.

          At TOPS Precision, our engineering team works closely with clients to analyze application requirements, production volumes, and finishing needs—ensuring the optimal alloy is selected for performance, efficiency, and cost-effectiveness.

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          Designing Guidelines for Zinc Machining

          Designing Guidelines for Zinc Machining

          When designing zinc components for machining, it’s essential to account for material behavior, machinability, and dimensional stability. At TOPS Precision, we guide our clients with proven design recommendations—including optimal wall thickness, tight tolerance control, and precise thread features—to ensure the production of high-quality, cost-effective parts that perform reliably and meet all functional requirements.

          Design Element

          Recommendation

          Reason/Benefit

          Wall Thickness

          Keep uniform; minimum ~0.8–1.0 mm

          Prevents warping, ensures structural integrity

          Fillets & Radii

          Use internal fillets ≥ 0.5 mm

          Reduces tool wear and stress concentration

          Bosses & Ribs

          Avoid overly tall or thin features

          Prevents vibration and improves stability during machining

          Draft Angles

          Use minimal or no draft when machining (vs casting)

          Enhances dimensional accuracy

          Hole Depth

          Limit depth-to-diameter ratio to ≤ 5:1

          Prevents tool deflection and breakage

          Threading

          Use standard thread sizes; allow a chamfer at the start

          Ensures clean thread entry and tool access

          Tolerances

          Design for achievable tolerances of ±0.025 mm or better

          Balances cost and precision

          Undercuts & Recesses

          Minimize or use specialized tooling

          Avoids tool collisions and reduces cost

          Surface Finish

          Avoid unnecessary polishing specs

          Zinc already offers a good surface finish after machining

          Assembly Fit

          Account for thermal expansion and zinc softness

          Ensures a reliable press-fit or mating

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            Expert Machining Tips for High-Quality Zinc Parts

            Here are some expert tips for high-quality zinc parts:

            • Minimize burrs by using ultra-sharp carbide cutting tools designed for soft metals.

            • Operate machines at high spindle speeds with low cutting pressure to maintain surface integrity.

            • Apply lightweight cutting fluids to ensure effective chip evacuation and temperature control.

            • Incorporate generous radii and rounded edges in part designs to enhance flow and machinability.

            • Maintain low clamping pressure during machining to prevent distortion in zinc’s soft, ductile alloys.

            Machinability of Zinc Alloys

            Zinc alloys rank among the most machinable materials, with machinability ratings exceeding 90%. At TOPS Precision, this translates to:

            • Minimal tool wear, extending equipment life

            • Faster cycle times, increasing throughput

            • Superior surface finishes, reducing secondary operations

            • Lower overall production costs, improving efficiency

            Alloys like Zamak 3 and Zamak 5 are particularly well-suited for CNC machining, producing clean, consistent chips and requiring minimal post-processing—making them ideal for high-volume, precision applications.

            How Does Zinc Machining Compare to Other Metals?

            Here is a comparison of Zinc with other metals:

            Property

            Zinc

            Aluminum

            Steel

            Machinability

            Excellent

            Very Good

            Moderate

            Corrosion Resistance

            High

            Good

            Low (needs coating)

            Weight

            Medium

            Light

            Heavy

            Cost

            Low

            Moderate

            High

            Surface Finish Quality

            Smooth

            Good

            Requires polishing

            Casting Compatibility

            Excellent

            Good

            Poor

            Options for Surface Finishing

            At TOPS Precision, we offer a range of advanced post-processing and finishing techniques to enhance both the functionality and appearance of your zinc components:

            • Polishing – Achieves a high level of surface smoothness and visual appeal for premium aesthetics.

            • Chrome/Nickel Plating – Adds a bright, durable finish with enhanced corrosion resistance for demanding environments.

            • Powder Coating – Provides long-lasting protection with uniform color and excellent surface durability.

            • Vibratory Finishing – Delivers consistent deburring and surface texturing, ideal for high-volume parts.

            • Passivation – Improves oxidation resistance, extending the lifespan of zinc parts in corrosive settings.

            Options for Surface Finishing

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              Applications of Zinc Machining

              At TOPS Precision, our expertly machined zinc components are used across a wide range of industries, including:

              • Electrical systems – contactors, connectors, and terminals requiring conductivity and corrosion resistance

              • Automotive – precision parts such as gear cases, brackets, and housing components

              • Consumer electronics – durable hardware enclosures and mounting structures

              • HVAC systems – heat-resistant, corrosion-protected structural components

              • Mechanical assemblies – high-precision enclosures and fittings for critical applications

              Advantages of Zinc Machining

              Zinc machining with TOPS Precision offers several key advantages:

              • Exceptional machinability with extended tool life on high-speed CNC equipment

              • High castability, allowing production of parts with complex geometries and fine details

              • Excellent corrosion resistance, ideal for long-term performance in harsh environments

              • Eco-friendly and fully recyclable, supporting sustainable manufacturing practices

              • Smooth surface finishes, ideal for direct plating with chrome, nickel, or decorative coatings

              Applications of Zinc Machining

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                Challenges of  Zinc Machining

                While zinc is highly machinable, it presents specific challenges that require expert handling:

                • As a soft metal, zinc can easily produce burrs if not machined with precision tools and optimized settings.

                • High clamping pressure may lead to part distortion due to zinc’s ductility.

                • Post-machining stress relief may be necessary to maintain dimensional stability.

                • Efficient chip evacuation is essential to prevent tool buildup and ensure a clean machining process.

                5 Tips on How to Save Cost on Zinc Machining

                Here are our proven strategies at TOPS Precision to help clients reduce production costs without sacrificing quality:

                1. Select the Right Alloy Early – Match the zinc alloy to your functional and structural requirements for optimal performance and efficiency.

                2. Design for Manufacturability – Avoid extremely thin walls and undercuts to ensure better machining results and lower production risk.

                3. Scale Up with Batch Production – Reduce per-unit costs by taking advantage of our high-volume production capabilities.

                4. Minimize Unnecessary Handling – Optimize workflows to focus on essential machining steps, reducing labor and material handling costs.

                5. Partner with Experts – Collaborate with our specialized team to plan machining operations for best results in terms of time, quality, and cost.

                Create Machined Zinc Parts with TOPS Precision

                At TOPS Precision, we combine high-speed CNC technology, skilled machinists, and rigorous quality standards to transform complex designs into reality. Whether you need intricate zinc connectors or large-volume industrial components, we deliver unmatched precision, reliability, and efficiency—on time and within budget.

                Simply send us your 3D CAD files or technical drawings to get started with a fast quote and engineering review.

                Our Servicing of Zinc Machining is Guaranteed

                All zinc machining projects at TOPS Precision are covered by our strict quality and delivery commitments:

                • ISO 9001:2015 Certified Quality System – Comprehensive process controls, in-process inspection, and continuous improvement ensure dependable results for every order.

                • Full Inspection & Material Traceability – Each batch is backed by 100% dimensional inspection (upon request) and traceability through heat numbers and material certifications.

                • 98% On-Time Delivery – Supported by real-time production tracking and optimized logistics to meet critical deadlines.

                • 96% Customer Satisfaction – We provide rapid after-sales support, including issue resolution within 24 hours and ongoing technical assistance to keep your production running smoothly.

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                  FAQs About ABS CNC Machining

                  Depending upon part geometry and volume, we can have tolerances as small as +/- 0.01mm.

                  Yes, and with proper plating in particular. The very common use of zinc is in terminals and connector housings.

                  Not necessarily, but we can use other coatings, such as nickel or powder coating, which help produce similar performance.

                  Yes, zinc is completely recyclable, and it does not require much energy to process it like other metals.

                  Average 7-10 days turnaround on request of accelerated services.

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