Unique: PROTIQ enables Additive Manufacturing from the Series Material Zamak 5

PROTIQ GmbH is revolutionizing the production of zinc components: Until now, zinc die casting has been the most common method for manufacturing prototypes and series components from the material Zamak 5. But this will change in the future, because from now on the 3D printing experts from Blomberg will be the first company worldwide to offer production using additive manufacturing as an alternative - and thus enable significant time and cost savings.

Zinc Components now from the 3D Printer

Since the invention of 3D printing in the 1980s, the technology has developed considerably and today it is hard to imagine industrial production without it. Through various processes, such as selective laser melting or laser sintering, prototypes and series components can now be manufactured from many different materials. From now on, PROTIQ also provides the material Zamak 5 for this purpose. 

The zinc alloy with proportions of aluminum, copper and small amounts of magnesium has so far primarily been processed in zinc die casting. In this process, molten metal is pressed at high speed and under high pressure into a previously made tool that defines the geometry of the component after it has cooled. The often manual production of the tool is very costly, which is why zinc die casting is usually used late in the product development process, because: Each geometry adjustment on a component requires the production of a new tool. The more complex the geometry of the component, the higher the cost accordingly. But this is now a thing of the past. PROTIQ has developed a worldwide unique process for additive processing of the series material Zamak 5, with the help of which the high time and cost expenditure typical for zinc die casting can be overcome from now on.

Enormous Time and Cost Savings through Additive Manufacturing

While zinc die casting takes weeks until the final component is ready, the product manufactured by PROTIQ using selective laser sintering is available to the customer within a few days. No expensive tooling is required, as the component is built up layer by layer from moldless material. If changes are required, all that is necessary in 3D printing is an adjustment of the 3D model. The production effort always remains the same. Functional prototypes can thus be produced economically right at the start of component development and modified at any time up to the final shape by adapting the CAD data with very little effort. This not only significantly shortens the development process and time-to-market, but also significantly increases flexibility.

In addition to the production of prototypes, additive processing of Zamak 5 has the potential to print components directly in series. The 3D printing process is also worthwhile for spare parts made of zinc. Previously, tools were required for their production, which had to be stored at great expense and repaired or newly manufactured in the event of damage. For additive manufacturing, only a corresponding 3D dataset is needed, and production can start without delay.

Service to the Highest Standards

PROTIQ offers the best prerequisites for producing small and medium-sized series under the highest quality standards, in addition to the production of prototypes. The certifications according to DIN-ISO 9001 and as an industrial additive manufacturing facility by TÜV SÜD ensure this. Thanks to PROTIQ's efficient processes, components can be delivered within a few working days. 

By the way, the surfaces of the additively manufactured components can be electroplated as usual - for example for a noble, high-gloss chrome look.