Martin van Leeuwen, who serves as Director of Technology and Market Development at the International Zinc Association (IZA), recently spoke with Foundry-Planet about the future prospects and current challenges facing zinc alloys. Based in the Netherlands, he oversees global initiatives aimed at expanding the use of zinc across a broad range of industries, including the diecasting sector. During the discussion, he highlighted IZA's latest market outlook, which forecasts growing demand for zinc diecasting through 2035. The International Zinc Association is an international industry organization headquartered in North Carolina, USA, with additional offices around the world.
In the interview, van Leeuwen identified several key drivers behind the expected increase in zinc demand. These include ongoing technological advances, demographic changes, the accelerating adoption of electric vehicles, continued urbanization, smaller average household sizes, and the expansion of middle-income consumer markets. He emphasized, however, that regional developments vary considerably. Europe, North America, and Asia each experience different demand patterns due to differences in population growth and economic performance, measured by gross domestic product (GDP). India, in particular, stands out as a market with significant growth potential. Its well-established diecasting industry, expanding middle class, favorable export conditions, and comparatively low labor costs position the country as a strong contender to become a major exporter of zinc diecast components.
Zinc Supports the Shift Toward Electrification and Sustainable Technologies
The growing adoption of electric vehicles is creating additional application areas for zinc diecast components. They are increasingly used in electrical and signal cable connectors, sensor housings, and a variety of other electrical systems. Renewable energy technologies also depend on zinc parts. In solar installations, for instance, zinc brackets and clamps are commonly incorporated into mounting systems. Because zinc combines excellent castability with high electrical and thermal conductivity, it is particularly well suited for electrical components and processing units.
Although these material advantages are well established within the industry, the International Zinc Association (IZA) continues to promote their wider recognition. The organization supports this effort through webinars and discussions with end-market associations, highlighting the benefits of zinc diecast components for different applications. One example is IZA's annual webinar held in cooperation with the Society of Automotive Engineers. Van Leeuwen also points to zinc's outstanding corrosion resistance, which ranks among the strongest of commonly used metals. In applications exposed to especially harsh environments, zinc castings can receive additional protection through electroplated metal finishes or organic coating systems. These surface treatments may also be chosen for decorative purposes when components remain visible in the final product, such as door handles, shower fittings, faucets, zippers, or watches.
Circular Economy Strengthens the Role of Zinc in Sustainable Manufacturing
Recycled zinc has become an increasingly important source for meeting global demand. While primary zinc production has remained relatively stable, the amount of zinc recovered through recycling has grown steadily, from around three million tons in 2010 to approximately five to six million tons today. These figures include only documented volumes from verified recycling sources. According to van Leeuwen, however, the actual amount is likely to be considerably higher. In several countries, recycling activities are well established but still take place within informal sectors where reliable documentation is limited. As a result, a substantial share of recycled zinc is not reflected in official statistics. Ongoing advances in collection systems, recycling technologies, and material sorting are expected to further increase the contribution of secondary zinc. At the same time, policy initiatives promoting circular economy principles continue to encourage greater use of recycled materials.
Questions about the quality of recycled metals are common, since recycled material can contain higher levels of impurities than primary metal. Van Leeuwen explains that modern upcycling technologies can effectively address this issue by restoring recycled zinc to a high level of purity. In practice, zinc recycling generally consists of remelting and, when required, additional refining processes that produce material suitable even for demanding applications. Compared with the production of primary zinc from mined ore, remelting requires substantially less energy and results in a significantly lower carbon footprint. Recycling therefore offers important environmental advantages, particularly in applications with high metal consumption. Van Leeuwen believes zinc is especially well suited to a circular economy because of its excellent recyclability and the large proportion of zinc products that remain in service for long periods. Looking ahead, he identifies improved product design to simplify disassembly and recycling, together with more advanced automated scrap-sorting technologies, as important opportunities to further increase recycling rates.
The Environmental Performance of Secondary ZAMAK Alloys
ZAMAK refers to a group of zinc-based alloys that combine zinc with aluminum, magnesium and, depending on the alloy grade, copper. The International Zinc Association (IZA) recently carried out a comprehensive lifecycle assessment of ZAMAK alloys produced from recycled zinc. According to IZA, this was the first study dedicated specifically to secondary ZAMAK alloys. It covered approximately 76% of secondary ZAMAK alloy production within the European Union, using operational data provided directly by participating manufacturers. The findings were encouraging: across the environmental indicators evaluated, secondary ZAMAK alloys consistently demonstrated a lower environmental impact than their primary counterparts.
The study attributes this improved environmental performance primarily to the lower energy requirements and reduced consumption of virgin raw materials associated with secondary alloy production. At the same time, cast components manufactured from recycled ZAMAK are expected to deliver a service life comparable to products made from primary alloys. Van Leeuwen explains that these outcomes were largely in line with the expectations of the IZA research team. Nevertheless, the assessment provides the first comprehensive dataset confirming, with measurable evidence, the environmental advantages and lifecycle performance of secondary ZAMAK alloys.
Zinc Diecasting Competes Through Efficiency and Performance
Zinc castings compete with a range of alternative materials, including aluminum, brass, selected engineering plastics, and extruded metal products. Nevertheless, zinc diecasting offers several manufacturing advantages. Components typically require only minimal machining after casting, with limited turning and trimming needed before they are ready for use. This reduces both production time and material waste, helping manufacturers lower overall costs. In addition, zinc's relatively low melting temperature and the short cycle times of diecasting machines contribute to efficient production and competitive manufacturing economics. Van Leeuwen highlights cost-effectiveness as one of zinc's key strengths.
At the same time, he notes that material substitution remains a challenge for zinc, as it does for virtually every engineering material. Although demand for zinc diecast components is expected to increase, competition from alternative materials means that continued innovation and cost competitiveness will remain essential for future growth. Reflecting on the broader outlook, van Leeuwen describes zinc as a versatile and sustainable material for cast components used in automotive applications, sanitary products, and building hardware. Its low melting point reduces the energy required during production, while its complete recyclability supports circular manufacturing. Within the diecasting industry, zinc is particularly valued for producing thin-wall micro castings with high precision. According to van Leeuwen, the combination of durability, long service life, and excellent manufacturing characteristics positions zinc diecastings strongly against competing materials and reinforces their long-term importance for sustainability and circular economy initiatives.
