Thixo Magnesium Injection Molding: A Smarter Way to Make Lightweight Parts

As global industries push for lighter, stronger, and more sustainable components, Thixo Magnesium Injection Molding (Thixomolding) is emerging as a highly capable solution. This process bridges the gap between metal casting and plastic injection molding—offering the best of both worlds, especially when magnesium is the metal of choice.

What is Thixomolding?

Thixomolding is a semi-solid metal injection process where magnesium alloy chips are fed into a heated, enclosed screw barrel. The material is brought into a thixotropic state (part-solid, part-liquid) and then injected into a mold under high speed and pressure. The result is precision magnesium parts with excellent surface finish, high strength, and minimal porosity.

Advantages of Thixo Magnesium Injection Molding

✅ Lightweight & Strong

Magnesium is the lightest structural metal, offering excellent strength-to-weight ratio—ideal for applications in automotive, electronics, aerospace, and medical devices.

✅ Clean & Eco-Friendly

• No SF₆ gas required

• Enclosed system with minimal oxidation

• Lower emissions and waste

• Recyclable feedstock and scrap

✅ Excellent Part Quality

• Minimal porosity and defects

• Superior dimensional control

• Good surface finish, often eliminating post-machining

• Consistent repeatability, even for complex geometries

✅ Fast Production

Thixomolding allows for shorter cycle times, making it suitable for medium to high-volume production.

How KOOLCRAFTS Supports Customers in Thixomolding

At KOOLCRAFTS, we bring a holistic approach to help customers successfully adopt and optimize thixomolding for their magnesium components.

🔧 Tooling & Component Support

We help design parts and tooling that are compatible with the unique flow characteristics of thixomolded magnesium, focusing on:

• Gate and runner planning

• Wall thickness balance

• Thermal management

• Mold cooling and ejection strategy

📋 Collaborative Development

Our team works closely with customers from the early concept stage to trial and validation, providing:

• Design for manufacturability (DFM) input

• Material selection advice

• Feedback on defect causes based on physical part observations

🤝 Open to Trials & Co-Development

KOOLCRAFTS is open to joint development programs where customers share:

• Physical part defects

• Rheology test results

• Process feedback

We combine these insights with our internal studies to help optimize your production process and tooling outcomes.

Partner with KOOLCRAFTS for a Confident Thixomolding Journey

As magnesium thixomolding gains traction, KOOLCRAFTS stands ready to support engineering teams with real-world guidance, technical collaboration, and a commitment to production success.

Let’s work together to build the next generation of lightweight, high-performance magnesium parts.