Custom Precision Zinc 5-Axis Machined Parts
Overview
The maximum 5-axis CNC machining size for zinc alloy parts is 800 x 600 x 900 mm, with freeform profile capability of 0.02 mm requiring a 3D model. Holes and surfaces in different directions on contoured housings, shaped connectors and angled mounting bases can be machined by adjusting tool orientation on the DMG 80mono 5-axis machine, reducing setup changes. The Matsuura MX-520 supports related multi-face operations. XCM CNC is certified to ISO 9001, ISO 13485, IATF 16949 and GJB9001C. The MOQ is 1 piece, prototypes take 3-7 days and standard lead time is 10-15 days. Equipment listed for this machining service includes DMG 80mono, Mazak i-100S, Matsuura MX-520, Jingshang 80 automatic lathe, Brother / Taichung / Qiao Feng CNC 3016-4A machining centers, Shenyang CK61125X2000 lathe.
Key Capabilities
- Materials: Zinc alloy; specified Zamak or ZA grade verified against the drawing and material certificate
- Tolerance: +/-0.003 mm (+/-0.00012 inch) on precision metal features; IT5 or IT6 accuracy, +/-0.01 mm shaft/bore fits; h6/H7 available
- Surface Finish: General milling Ra 3.2 um; precision milled and cosmetic faces Ra 1.6 um; polished faces Ra 0.2 um; Ra 0.015 on critical polished areas by drawing review
- GD&T: Freeform profile 0.02 mm; hole-pattern position 0.015 mm; perpendicularity 0.02 mm / 1000 mm; flatness 0.02 mm
- Max Size: 5-axis machining up to 800 x 600 x 900 mm; multi-face single setup up to 600 x 1200 x 500 mm
- Surface Treatment: Deburring, polishing, 80#-220# sandblasting; zinc-compatible plating 3-20 um, depending on drawing and order requirements
- Thread: Internal M1.4 and external M2.0 up to M220; NPT / BSP / G / PT pipe threads; go/no-go gauge inspection
- Precision Limit: +/-0.003 mm on small critical features; roundness 0.006 mm; hole-pattern position 0.01 mm (specific features, by drawing review)
Zinc 5-Axis Freeform Contours with 0.02 mm Profile Accuracy
The DMG 80mono can machine zinc alloy contoured housings with freeform profile capability of 0.02 mm and a maximum machining size of 800 x 600 x 900 mm. Specify profile according to ISO 1101 and use the 3D model as the theoretical surface. Die-cast surface stock is often uneven, so scanning or indicator alignment is performed first, followed by allocation of finishing allowance to avoid locally milling through the casting skin.
Zinc Multi-Face Single-Setup Machining for Angled Holes
Maximum multi-face single-setup size is 600 x 1200 x 500 mm, allowing angled holes and mounting faces in different directions on zinc alloy parts to be machined from a common datum. Cross-face hole-pattern position can reach 0.015 mm and perpendicularity 0.02 mm / 1000 mm. Parting lines and gate remnants should not serve directly as clamping surfaces. A process clamping feature is generally milled first, then the part is flipped and clamped.
Zinc Deep Cavities, Ribs and Undercuts in 5-Axis Parts
Zinc alloy housing cavities normally support a depth-to-width ratio of 4:1, increasing to 5:1 with extended tools. For cavities 40 mm deep, an internal radius of at least R1.0 mm is recommended; shallow cavities have a minimum internal radius of R0.5 mm. Minimum rib thickness is 0.8 mm with a height-to-width ratio of 8:1. Undercuts can be machined, but inaccessible areas require multiple setups or EDM.
Zinc Curved Cosmetic Surfaces and 3D Scan Inspection
Zinc alloy cosmetic surfaces can receive mirror, bright or matte finishes, with polished surfaces at Ra 0.2 um and sandblasting grades of 80#-220#. Surface profiles can be checked using a Hexagon Inspector Classic 06.08.06 CMM, 3D scanning or profile inspection according to the order. Texture, scratches and color variation are assessed against customer cosmetic standards or samples.
Specifications
| Product Name | Custom Precision Zinc 5-Axis Machined Parts |
|---|---|
| Manufacturer | XCM CNC (Shenzhen Xinchuangmeng Co., Ltd), Shenzhen, China |
| Factory Location | Shenzhen, Guangdong, China |
| Quality System | ISO 9001, ISO 13485, IATF 16949, GJB9001C |
| Machining Process | 5-axis CNC machining of die-cast zinc contours, angled faces and multi-direction features |
| Material | Zinc alloy |
| Material Grade | Specified Zamak or ZA grade by drawing, standard and material certificate; no assumed grade equivalence |
| Tolerance | +/-0.003 mm on precision features; IT5/IT6; profile 0.02 mm; hole position 0.015 mm |
| Surface Roughness | Ra 3.2 / 1.6 / 0.2 um by surface; Ra 0.015 on critical polished areas by drawing review |
| Surface Treatment | Deburring, polishing, sandblasting 80#-220#; zinc-compatible plating 3-20 um, depending on drawing and order requirements |
| Max Part Size | 5-axis 800 x 600 x 900 mm; single-setup multi-face 600 x 1200 x 500 mm; 3-axis travel 3000 x 1600 x 1400 mm |
| Inspection | Equipment: Hexagon Inspector Classic 06.08.06 CMM, WanHao Rational VMS-3020G, TRIMOS 600L height gauge; 3D scan and profile inspection; Documents: Dimensional inspection report; CMM / FAI / third-party report by order |
| Application | Curved housings, shaped hardware connectors, angled mounting housings and model exterior components |
| Key Features | Freeform contours, angled faces, multi-direction holes, cross-face fits and accessible undercuts |
| Critical QC Requirements | Model revision, datums, surface profile, cross-face position, thin-wall distortion and visible surface texture |
| MOQ | 1 piece |
| Typical Lead Time | Prototype 3-7 days; standard 10-15 days depending on complexity and quantity |
| Drawing Formats | STEP, IGES, STP, DWG, PDF with dimensions |
Applications
Shielding Housings with Curved Forms and Angled Holes
Typical parts: Contoured shielding housing, angled connector interface
Curved surfaces, angled holes and multi-directional mounting faces need tools to approach from different directions. Five-axis machining can complete them in one setup, with cross-face hole position controlled to 0.015 mm. Shielding effectiveness is defined by product design and verification requirements.
Contoured Handle Connectors and Lock Housings
Typical parts: Contoured handle connector, die-cast lock housing
Zinc die-cast parts with angled connection faces and curved cosmetic surfaces can have those surfaces polished to Ra 0.2 um before plating. General planes and single-direction holes still use 3-axis operations to save machining time. Drawings or samples define load, appearance and coating requirements.
Sensor Housings with Multi-Directional Mounting Features
Typical parts: Multi-direction sensor housing, angled mounting base
Curved interfaces, angled mounting faces and hole patterns in different directions on small housings are interrelated. They can be machined from common datums on the DMG 80mono according to the model, with mounting-face perpendicularity of 0.02 mm / 1000 mm. Overall locating accuracy and load capacity depend on the sensor assembly design.
Contoured Automotive Interior Housing Prototypes
Typical parts: Curved interior equipment housing, multi-face assembly cover
For die-cast prototypes combining curved forms and mating features on several faces, 5-axis machining produces faces in different directions from the 3D model, with profile of 0.02 mm. 3D scanning can compare the part with the model. Temperature, load, environmental and functional requirements are evaluated for the project.
Contoured Housing Components for Model Equipment
Typical parts: Scale-model contoured housing, angled mounting component
When cosmetic surfaces and angled mounting holes extend in several directions, the die-cast form can be retained while only specified features are machined. Maximum cavity depth-to-width ratio is 5:1. Access to cavities, undercuts and obstructed faces must be evaluated against the model.
Why Choose Us
Quality Systems and Five-Axis Equipment
Projects operate under ISO 9001, ISO 13485, IATF 16949 and GJB9001C quality systems. Equipment resources include DMG, Mazak, Matsuura and Brother, allocated according to complex-surface and process requirements.
Machining Support for Curves and Multi-Directional Features
Five-axis machining supports tool approaches to housing curves, inclined faces and multi-directional holes, together with edge breaking and evaluation of plating suitable for zinc substrates. Fixture obstruction and undercuts still require model-based review.
Tiered Equipment Strategy for Low-Cost CNC Machining, Quality-Assured Production
XCM CNC uses four tiers of CNC equipment from mainland China, Taiwan, Japan, and Europe and the United States. On the same zinc alloy housing, single-direction faces and general holes use mainland Chinese or Taiwanese machines, while freeform surfaces and cross-face hole patterns use imported equipment such as DMG and Mazak. Machines follow feature accuracy rather than assigning the whole part to 5-axis machining, reducing cost while meeting drawings.
Manufacturability Feedback with the Quote
After receiving the 3D model, the quote also identifies inaccessible undercuts, deep cavities with undersized internal radii and overly thin ribs, with adjustment suggestions. Addressing these issues during quotation avoids discovering them during prototyping and reduces repeated model revisions.
Third-Party Inspection Reports for Complex Surfaces
In addition to our dimensional inspection reports, third-party inspection reports can be issued according to the order when requested. This suits projects requiring independent data for end customers or certification bodies.
FAQ
When does a zinc housing benefit from five-axis machining?
Five-axis machining is worth evaluating when curves, inclined faces and multi-directional holes require different tool approaches and repeated setups would increase datum changes. Conventional single-direction faces and holes usually only need 3-axis machining.
How do you choose between 3+2 positioning and five-axis machining?
Angled holes and inclined faces generally use 3+2 positional machining, while continuous freeform surfaces use simultaneous 5-axis machining. Maximum multi-face single-setup size is 600 x 1200 x 500 mm. The specific route is planned from the 3D model.
Can five-axis machining reach every undercut in a zinc casting?
Access to every undercut cannot be guaranteed. Tool length, fixture obstruction and part orientation require model-based checks. Additional setups or EDM may be needed.
Is five-axis machining more expensive for zinc parts?
Five-axis machining has a higher hourly cost than 3-axis machining, but only curves and cross-face features are assigned to it. Other operations stay on 3-axis machines. Quotes calculate costs feature by feature rather than pricing the entire part as 5-axis work.
Can I order a single 5-axis zinc part for design verification?
Yes. The MOQ is 1 piece, with prototypes usually taking 3-7 days. Validation parts and subsequent batches use the same inspection methods for comparable data.
Can you provide a third-party inspection report?
Third-party inspection reports can be provided according to the order. Specify inspection items and report requirements during inquiry so the schedule can be planned.
What are the payment, shipping and packaging options?
Payment options: T/T, PayPal, Western Union. Shipping options: DHL / FedEx / UPS / Sea freight. Packaging: Foam + carton; wooden case on request.
Request a CNC Machining Quote from XCM CNC
Send us your drawings. Our team will review the file and reply with a machining quote. MOQ: 1 piece, with competitive low-cost pricing.
