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Zinc Machining Services by TOPS Precision

TOPS Precision specialises in high-performance zinc machining that is optimised in terms of strength, detail, and efficiency. We produce precision zinc parts designed to satisfy the requirements of automotive, electronics, HVAC, and consumer product industries with the help of the advanced CNC options and a team of skilled engineers.

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    Whether you require standardized or custom-made zinc parts, either in low-volume prototyping or high-volume production, Quality, Fast Turnaround, and Tight Tolerances are a promise. Since the start of our process with material selection through the final inspection, we are your one-stop shop for everything to do with zinc.

    Our Zinc Machining Services will provide you with;

    • High-Speed Accuracy – Perfectly tailored to the machinability of zinc, achieving fast results and close tolerances.
    • Extraordinary Finishes – Unpolished, corrosion-resistant finishes that can also be plated or assembled.
    • Broad Material Capability – Ability to machine a variety of Zamak and ZA alloys.
    • End-to-End Legislation – Complete support on material selection to manifolding and delivery.

    What are Zinc and Its Alloys?

    Zinc is a corrosion-resistant, bluish-white metal that is highly formable, recyclable, and cost-effective. Pure zinc [ochre or gray] finds very little use without alloying elements such as aluminum, copper, or magnesium to join it in the formation of Zamak and ZA alloys. These alloys can be appreciated because of their strength, wear resistance, and ability to be cast or machined.

    What Is Zinc Machining?

    The machining of zinc includes CNC milling, turning, drilling, tapping, and finishing. Since they are soft and ductile, cutting zinc alloys is very easy. Nevertheless, to prevent the occurrence of burrs, deformation, or tool buildup, exact process control is mandatory.

    Here at TOPS, we have a CAD model and CNC equipment that is high-speed and configured to work with soft metals. We choose fine carbide cutters, optimum feeds and speeds, and lubricating oils in order to provide clean cutting operations, reduced wear, and outstanding precision.

    How Zinc Machining Works?

    Zinc machining is when Zinc or Zinc alloy components are shaped using precision tools, usually involving CNC (Computer Numerical Control) processes. Zinc is extremely machinable and thus, elements such as cutting, drilling, milling, turning, and tapping can be done at high speed with little tool wear. CAD plays a major role in machining since part designs are generated using the CAD models and converted into accurate tool paths that instruct their cutting implements.

    CNC lathes and mills CNC lathes and mills cut zinc billets or zinc castings off in layers to render tight tolerances and smooth surface finishing. Sparingly, cooling and lubricating fluids are applied as zinc emits heat during cutting. Zinc is soft and ductile, and so high feed rates and sharp tools are necessary to prevent burring or deforming. It is subjected to post-processing such as deburring, polishing, and coating to improve durability and looks.

    Properties of Zinc?

    Here are some of the properties of zinc:

    1. Excellent Machinability

    Zinc alloys belong to the most machinable of all metals, with a rating generally above 90 percent. This enables higher cutting speeds, increased tool life, and productive production runs-this makes zinc an excellent material to utilise in high volume CNC machining.

     

    2. Corrosion Resistance

    Zinc has a natural resistance against oxidation by developing a protective layer of zinc oxide. This passive shield safeguards components against moisture and atmosphere as well as protects them in cars, outdoors, and industrial applications.

     

    3. Low Melting Point

    Zinc melts at about 419.5°CC (7787°F, making it suitable for casting and the thermal process. The property enables simpler mold filling, reduced energy requirement in the manufacturing process, and compatibility with die-casting activities.

     

    4. Dimensional Stability

    Zinc alloys are low-shrinking and stable in thermal expansion, which facilitates burning to close tolerances. This renders them as applicable to precision parts, which need good fits and minimum deformation with time.

    5. Good Strength and Toughness

    Zinc alloys are strong and ductile in a fair balance. They are not as tough as steel, though, and are sufficient to be used on structural parts, notably if one uses high-performance alloys, such as ZA-12 or ZA-27.

    6. Electrical Conductivity

    Zinc is a fair conductor, and electrical parts containing zinc (terminals and housings) are common. It is also more practical where corrosion resistance and conductivity should work in tandem.

    7. High Density

    The density of Zinc is relatively high (approximately 6.6 g/cm³) and provides machined components with a heavy, solid nature. This is a desirable property in consumer goods, fixtures, and handles, where weight signifies quality.

    8. Recyclability

    The metal is recyclable up to 100 percent without affecting the performance. It is meltable and reusable, which means it is economical as well as eco-friendly.

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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

      Excellent in 2D and 3D profiles, enclosures, housing, and mounting plates. Precision contours are done using multi-axis milling.

      2. CNC Turning

      Applied to cylindrical zinc components, such as shafts, bushings, and pins. Provides superior roundness and surface treatment.

      3. Tapping and Drilling

      Holes and threads can be added to provide fasteners or connectors, or pressure-tight systems, cut clean and exact.

      4. Reaming And Boring

      Applied to adjust hole sizes and to obtain the perfect alignment, particularly in the case of mechanical assembly.

      5. Deburring

      Takes away cutting corners and machining remains to enhance functionality, safety, and appearance.

      6. Engraving and Profiling

      Gives design and serial numbers or brand smacks with great accuracy.

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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:

        • Zamak 3:Most suitable with cosmetic part, die-cast type, and close tolerances.
        • Zamak 5:Applicable in structural or stress parts.
        • Zamak 7:Ideal in case of elaborate or fine-walled parts.
        • ZA-8: Perfectly fit in high-impact or mid-load applications.
        • ZA-12/27: Excellent on heavy wear, high-stress pieces requiring repeated flexibility.

        We assist our clients in the analysis of use cases, production volumes, and finish requirements in order to choose the most suitable alloy.

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          Designing Guidelines for Zinc Machining

          In designing zinc that will be machined, one should always be keen on considering the material behavior, its machinability, and dimensional stability. These are some of the guidelines on wall thickness, tolerances, thread features, etc that can provide high-quality quality cheap parts.

          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 using sharp carbide tools.
            • Use high RPM and low cutting pressure on machines.
            • Use light cutting fluids to control chip clearance.
            • Part design should have wide radii and rounded edges.
            • Clamping pressure should be low to avoid distortion in soft alloys.

            Machinability of Zinc Alloys

            Zinc alloys are some of the best materials to machine; most are higher than 90% machinability. This means:

            • Minimal tool wear
            • Faster production
            • Better finishes
            • Reduced costs of operation

            Zamak 3 and Zamak 5, especially, are CNC-friendly and leave clean chips with minimal post-processing.

            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

            The following post-processing and finishing techniques are offered:

            • Polishing:Enhances smoothness and looks.
            • Chrome/Nickel Plating:Provides a glossy finish and corrosion resistance.
            • Powder Coating: Long-lasting, color shielding.
            • Vibratory Finishing:Consistent deburring and texturing.
            • Passivation:Increases the oxidation resistance.

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              Applications of Zinc Machining

              Here are some of the common applications for Zinc machining;

              • Electrical, contactors, and terminals
              • Car components (gear cases, brackets)
              • Consumer electronics and hardware boxes
              • HVAC components
              • Accurate mechanical enclosures

              Advantages of Zinc Machining

              The following are the advantages of Zinc machining;

              1. Machinability with the tool life of high-speed machines.
              2. Complex geometry castability Amazonas ouro 8 Amazonas gold 8
              3. Fine corrosion resistance
              4. Recycling and eco-friendliness
              5. Smooth-finish adaptable to direct plating

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                Challenges of  Zinc Machining

                Here are some of its challenges;

                • Soft material which would give burrs without proper machining
                • Possibility of deformation in high clamping pressure
                • May have to relieve stress by post-machining
                • Requires delicate chip evacuation to prevent tool sticking

                5 Tips on How to Save Cost on Zinc Machining

                You can follow these tips to effectively reduce the cost.

                • Select the Appropriate Alloy earlier -Match material with application requirements.
                • Design for Manufacturability -Design is to have walls that are not too thin or undercuts.
                • Make Batch Production – Cost effectiveness by upscaling production.
                • Reduce Unnecessary Handling – Use only the most needed router.
                • Work with the Professionals- Seek the expertise of the specialized community to plan effectively.

                Create Machined Zinc Parts with TOPS Precision

                TOPS Precision provides unimaginable quality, and we can help you develop complex zinc connectors or high-volume industrial components. We also mix high-speed CNC equipment, skilled machinists, and quality assurance standards to create the concept into reality on schedule and within budget.

                To get started, please send us your 3D designs or engineering drawings.

                Our Servicing of Zinc Machining is Guaranteed

                All the products we manufacture are covered by us. Our zinc machining services are supported by:

                • Quality control that satisfies ISO 9001
                • Inspection reports and material traceability
                • Delivery commitment on time
                • Customer satisfaction and after-sales support ensure

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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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