The product designers of zinc die castings have been using outdated technical information relative to minimum wall thickness possible with modern die casting techniques. Large decorating zinc die castings are currently in volume production with average wall thickness of 0.045 in. and local areas as low as 0.030 in. Case studies are detailed on four production die castings. Material cost savings on one casting could exceed $80,000 compared to product design with conventional wall thickness of 0.060 in. minimum. The value engineering concept is recommended to the designer as a guide for evaluating minimum acceptable wall and rib thickness, and boss diameters. Research programs are underway to provide design and production data for future zinc die castings.