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Magnesium Thixomolding

The demand for durable, lightweight products has driven the significant growth of magnesium thixomolding. Its many advantages make it a suitable choice for manufacturing parts found in automotive, consumer products, defense, electronics, handheld devices and sports equipment. As a result, magnesium thixomolding is becoming the favored capability in producing various products in all markets.

Advantages of Magnesium Thixomolding


Magnesium thixomolding produces thinner, lighter and stronger parts than are possible with engineered plastics and die casting. This process also offers numerous cost advantages over other production methods. These advantages include higher product yield, increased die life, lower utility cost and consistency of process.

Additional advantages of magnesium:

  • High strength-to-weight ratio
  • Good machinability
  • Good heat-transfer characteristics
  • Non-magnetic
  • Higher temperature applications than plastic
  • Easier to recycle than plastic
  • Excellent damping capacity

With more than 50 years of injection molding experience, Molex provides solutions reflective of our extensive capabilities in key molding technologies and processes. Through effective collaboration and applied expertise, we deliver superior products with maximum value to meet our customers’ growing demands.

Magnesium Thixomolding Process


  1. Magnesium chips are fed into a heated barrel containing argon to prevent oxidation.
  2. The magnesium is heated (approximately 560 to 630°C), creating a thixotropic slurry.
  3. Within the barrel, a rotating screw propels the material forward.
  4. The slurry is forced into a preheated metal mold to produce a net or near-net shape part.

Traditionally, die-cast molding results in product yields of 50% and creates waste – scrap, slag, and dross. The thixomolding process, improves product yields to 90%, while eliminating waste and loss of product to melting. This process provides a worker- and environment-friendly atmosphere and can easily integrate into automated manufacturing processes to produce metal and metal/plastic assemblies.

Thixomolding Versus Die Casting

  • Lower porosity
  • More favorable parts for maintaining air pressure
  • Tighter tolerances (NADCA Precision Tolerances)
  • Parts with fewer draft features
  • Generally longer tool life
  • Product yields at 90% (compared with die casting’s 50% product yields)

Design through Manufacturing


At Molex, our Design Develop Center offers design optimization (DFM) and incorporates a design phase to identify product, environmental, function, finish and cosmetic requirements.

Quality Systems

  • ISO 9001 certified
  • IATF 16949 certified
  • Control plans, FMEA, operator guides, visual inspection
  • SPC for product validation and process control

Internal Secondary Capabilities

  • Overmolding
  • Form in place gasketing
  • Machining
  • Deburring
  • Hand finishing
  • Assembly

Additional Capabilities

  • Proto typing
  • Conversion coating
  • E-Coat
  • Wet paint
  • Dry powder finish
  • Plating

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