Zinc Die Casting Accelerates in Large and Small Cars

The allure of automobiles captures the hearts of both adults and children. From brand preferences to model choices, and discussions on electric mobility, automotive topics stir passion. It's no wonder phrases like "Germans' favorite toy" or "best friend on four wheels" have become commonplace.

For some, the love for cars goes even further: they push their sports cars to the limit on racetracks or collect exquisitely detailed miniature technology gems. Many are aware of the value, design, feel, and appearance that zinc die casting brings to large and small cars. However, the inherent strengths of components produced by this method are often less known.

Showcase Dreams Made of Zinc Die Casting

Fans often develop a passion for fast cars long before they're old enough to drive. Didier Rollez is no exception. As with many young boys, Matchbox cars and the Carrera racing track were his favorite toys.

Though the Carrera track is no more, Rollez's love for model cars remains. "I'm not specialized in any particular era, but my showcases tend to feature more classic cars than modern classics. It's the intricate details and the substantial feel of the miniatures in my hand that matter to me," says the avid collector.

Zinc die casting has been a staple in the model car realm since the 1930s, gradually replacing tin toys: Dinky Toys started the trend in 1934 with 1:43 scale models, previously used only for model trains. Matchbox began its success story in the market in 1948.

By the 1970s, the trend shifted towards larger model cars as collectibles — because the customers, now more adults than children, demanded high-fidelity designs in premium finishes and heft. Requirements that zinc die casting continues to meet with ease, especially when considering mass production and cost factors, where the method is in pole position.

Racing Inspires Production

Speaking of pole position, motorsport is the pinnacle of the automotive world and offers a thrilling experience. Luc Gebeelen of the Belgian Porsche Racing Team can attest to that. His team regularly competes for podium spots on racetracks in Belgium and the surrounding area, such as the Nürburgring, self-proclaimed as the most beautiful piece of asphalt between the poles.

"But it's not just about accelerating," Gebeelen clarifies, "one must also understand how the car behaves on the track, know its limits, and its construction to make necessary adjustments."

Motorsport, especially Formula 1, often leads to innovations that later become standard in production vehicles: new materials and systems are tested as opportunities arise.

For example, motorsport is far ahead in lightweight construction compared to production vehicles. This theme has become vital in the automotive industry's quest to reduce CO2 emissions. Cast components play a significant role in lightweight construction, so reducing the weight of cast parts without significantly changing material properties is particularly interesting.

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Lightweight Construction with Zinc Die Casting

In zinc die casting, two paths are pursued: using zinc foam for composite bodies or filling lightweight parts combines many positive properties of traditional zinc die casting but with the low intrinsic weight due to the internal foam structure, limited to the core of the components. Towards the edges, the porosity becomes progressively finer, transitioning into a solid cast surface that can be polished and electroplated. The result: a 50 per cent material and weight saving, combined with decorative surfaces.

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The second method is thin-wall casting, which utilises technical properties while simultaneously minimising weight. High-fluidity alloys have been developed for this purpose. They have the same good mechanical, electrical and thermal conductivity properties as conventional alloys, but are up to 40 per cent more flowable. Thanks to these adaptations, wall thicknesses of up to 0.5 millimetres can now be realised as standard, and even 0.3 or 0.2 millimetres are technologically feasible. This is a major advantage, especially for the electronics sector, where components have to be designed with extremely thin walls.

Potential for electromobility

A look back at motorsport: even if it may not seem like it at first, sustainability, environmental protection, efficiency and electrification are playing an increasingly important role here too - another aspect that will have an impact on electromobility in general. And thus on the potential where zinc die casting will be used in the future: "The more e-cars come onto the market, the higher the proportion of lightweight cast parts is likely to be. The range of possibilities for zinc die casting is broad here. It ranges from optimised components for controlling conventional engines to structural parts in the body and components for electric drives," says Petar Marovic, die casting specialist.

However, the electronics housings and sensors required in large quantities for electric cars also expand the spectrum for this process. Marovic says: "It's not just people who make demands on cars - cars have always made demands on people too. Especially in terms of expertise when it comes to new and further developments. The zinc die-casting industry is well positioned for the future in this area."

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Showcase Dreams Made of Zinc Die Casting

Racing Inspires Production