Quality Control for Zamak Die Casting

ISO 9001:2015 · 100% in-process inspection · full lot traceability

Micrometal Quality Control: zero defects on 75,000 kg/month

Quality control in zamak (zinc alloy) die casting is not an end-of-line operation: it is an integrated system that starts with raw material certification and reaches the validation of the lot delivered to the customer. Since 1991, Micrometal applies an ISO 9001:2015 certified quality system covering the entire production chain across 11 machines (7 standalone presses + 4 Frech DAW 80 robotic cells) with a 75,000 kg/month capacity.

The declared goal is zero defects per customer, supported by a mix of 100% inline automatic checks on robotic cells and AQL-based dimensional sampling inspections on standalone presses. For critical components (automotive, security, medical sectors), we activate intensive audits with dedicated control plans and lot-piece traceability for each production run.

The 5 phases of Micrometal quality control

1. Raw material acceptance — every zinc alloy ingot EN 12844 ZP3, ZP5 or ZP2 arrives with a 3.1 supplier certificate (chemical composition, lot). 100% documentary verification and spectrometer sampling on critical lots.
2. Pre-production (DFM) — analysis of the customer drawing for die casting feasibility, prevention of typical defects (porosity, cold shuts, undercuts, sink marks) via mold filling simulation and FAI/PPAP validation.
3. In-process inline — on the 4 robotic cells, every part passes under HD camera for visual + dimensional check with automatic rejection of non-conformities. On the 7 standalone presses, the operator performs AQL sampling checks with calipers, optical comparators, and profile projectors.
4. End-of-line — final dimensional check with calibrated instruments (digital calipers, micrometers, Brinell hardness tester) plus leak test or functional test where required. For critical components: 3D measurement on CMM with full dimensional report.
5. Traceability and archive — every lot has a unique identifier; certificates, calibration records, control plans and dimensional reports are kept for at least 10 years (longer on request for IATF automotive customers).

Quality control instruments in the Micrometal lab

The internal metrology lab is equipped to cover the full spectrum of inspections typical of zamak die-cast components: dimensional, geometric, form, surface, and mechanical. Periodic instrument calibration follows ISO 17025 through an external accredited body.

For components requiring tight tolerances (±0.05 mm or lower), dimensional control is performed on CMM at a qualified external lab, with full dimensional report attached to the lot.

Quality certifications and standards

The Micrometal quality system is structured to meet the requirements of major industrial and sector-specific standards, in line with the demands of the most rigorous customers in automotive, security, electronics, and medical markets.

• ISO 9001:2015 — quality management system certified since 1996 (over 25 years of continuity) — see quality certifications
• IATF 16949 in roadmap — implementation underway for OEM automotive customers
• RoHS / REACH — hazardous substance compliance verified on 100% of alloys used
• Conflict Minerals (3TG) — CMRT declaration available on request
• UNI EN ISO 17025 — accredited external calibration lab for metrology instruments

For components destined for regulated sectors, the full quality documentation is available on request: certificate of conformity, dimensional report, 3.1 alloy certificate, PPAP (level 1-5) or FAI (First Article Inspection) per AS9102.

Micrometal Quality KPIs: the numbers we monitor

Quality is not an abstract concept: we measure it daily with quantitative KPIs shared with the customer through periodic audits. Data transparency is part of our approach.

• Internal defect rate (PPM) — target < 500 PPM for standard production, < 100 PPM for automotive customers
• Customer defects — target zero, monitored per customer with 8D reaction plan in case of NC
• OTD (On-Time Delivery) — > 96% deliveries within confirmed date
• Process Cpk — > 1.33 on critical dimensional characteristics declared on the drawing
• FAI/PPAP first-pass yield — > 90% of pre-production lots approved on first submission

For each project we activate a dedicated control plan at industrialization, shared with the customer and adapted to component criticality. For the upstream production process detail: complete zamak die casting guide.