Hey everyone,

I'm in the early stages of a new project designing some custom hardware components (thinking things like knobs, levers, and small structural brackets) and I'm trying to decide on the best material for die casting. The usual debate between Zamak (a zinc alloy) and Aluminium keeps coming up.

I've used aluminium before for its strength-to-weight ratio and corrosion resistance, but I've also heard a lot about Zamak being cheaper and easier to cast with better surface finish for plating. I'm trying to get a clear, practical breakdown beyond the marketing fluff.

Cost: I know Zamak is generally cheaper, but by how much when you factor in material and production?

Strength & Weight: Aluminum is lighter, but is Zamak actually stronger in terms of tensile strength?

Manufacturing: Which one allows for thinner walls and more intricate details?

Finishing: How do they both take to painting, powder coating, or chrome plating?

I found a pretty solid article that breaks down a lot of this and even throws Brass into the mix for comparison. It covers the key properties, applications, and pros/cons in a way that's actually useful for making a decision.

Check it out here: Zamak vs Aluminium vs Brass: What's the Difference?

It helped me understand that it's not about one being “better,” but about which is better for the specific application. For me, the surface finish might be the deciding factor.

What's your experience? Have you chosen one over the other for a project and regretted it? Or been pleasantly surprised? I'd love to hear some real-world insights.