Magnesium Thixomolding Machines for Lightweight Automotive Parts

As the automotive industry continues to pursue lower emissions, improved fuel efficiency, and enhanced performance, the demand for lightweight materials has surged. Among these, magnesium alloys stand out for their exceptional strength-to-weight ratio. However, processing magnesium requires highly specialized processes—this is where magnesium thixomolding machines come into play.

For automotive manufacturers aiming to reduce vehicle weight without compromising durability or performance, magnesium thixomolding offers a safe, efficient, and highly precise production method. This advanced metal forming technique delivers distinct advantages, particularly for high-volume automotive production.

YIZUMI, a global leader in die casting and metal forming technology, offers high-performance magnesium thixomolding machines engineered to meet the stringent demands of modern automotive part manufacturing.

1. Why Magnesium Matters in Automotive Applications

Magnesium is the lightest structural metal in use today—approximately 33% lighter than aluminum and 75% lighter than steel. When used in structural or functional automotive parts, it contributes to:

• - Fuel efficiency improvements through overall weight reduction
• - Better power-to-weight ratios in EVs and high-performance vehicles
• - Lower CO₂ emissions in combustion-engine vehicles
• - Increased design flexibility in casting complex geometries

Despite its low weight, it delivers strong mechanical properties and excellent vibration damping. These characteristics make it ideal for automotive applications such as steering wheels, instrument panels, transmission housings, and seat frames - as automakers transition to electric and hybrid platforms, every kilogram saved matters.

Mg-Thixomolding Machine For Automotive Lightweighting

2. What Is Magnesium Thixomolding?

Thixomolding is an advanced semi-solid metal forming process that addresses the limitations of conventional magnesium processing. Instead of pouring molten metal into molds, thixomolding feeds solid magnesium alloy slugs into a machine, where they are heated into a semi-solid state and then injected into a mold cavity under high pressure.

This closed-loop system offers significant improvements in safety, quality, and efficiency.

Key Benefits:

• - Near-net-shape part production
• - Lower oxidation and safety risks
• - Minimal porosity, superior mechanical properties
• - Fast cycle times and low scrap rates
• - Cleaner, safer work environment

3. Magnesium Thixomolding vs. Traditional Die Casting in Auto Part Manufacturing

While conventional die casting and metal forming techniques have long served the industry, they pose certain limitations when it comes to magnesium alloys—primarily safety risks related to magnesium’s flammability in molten form and challenges in forming precision parts.

Magnesium thixomolding overcomes these challenges through a semi-solid injection process that combines the control of plastic injection molding with the strength benefits of metal. To better understand how magnesium thixomolding compares with conventional methods, see the detailed comparison below:

For automotive suppliers, magnesium thixomolding leads to higher yields, fewer post-processing steps, and more design freedom.

4. Applications of Mg-Thixomolding in the Automotive Industry

With the use of advanced magnesium thixomolding machines, manufacturers are able to produce a variety of lightweight and high-performance automotive components, including gearbox housings, steering column parts, dashboard cross beams, HVAC housings, pedal brackets, etc. These components offer significant advantages in weight reduction, structural strength, and design flexibility.

Key applications include:

• Seat frames – lighter seats contribute significantly to total weight reduction
• Transmission components – high strength and precision reduce wear and improve performance
• Instrument panels – magnesium’s formability allows sleek, modern designs
• Steering wheels & brackets – lightweight yet structurally sound under stress
• Battery housings – increasingly relevant in EV platforms for thermal and structural performance

Automotive OEMs are increasingly moving beyond cosmetic applications and adopting magnesium thixomolding for structural parts, where the material’s combination of low weight and high mechanical performance provides unparalleled benefits in next-generation vehicle design.

Mg-Thixomolding for Central Control Dashboard Bracket

5. Key Benefits of Mg-Thixomolding Machines for Automotive Projects

Exceptional Weight Reduction: Every kilogram saved in a car helps reduce fuel consumption or extend EV range. Thixomolded magnesium parts can achieve up to 60% weight reduction over steel and up to 30% over aluminum.

Consistent Quality and Precision: The thixomolding process ensures tight dimensional tolerances, making it ideal for high-precision parts. It minimizes shrinkage, porosity, and post-processing requirements.

Lower Energy Consumption: Compared to traditional die casting, magnesium thixomolding uses lower melt temperatures, resulting in energy savings of up to 40% during the molding process.

Cleaner Production Environment: No SF₆ gas is required, and magnesium chips are recycled more efficiently. The closed-loop nature of the process reduces emissions and environmental risks.

High Automation Compatibility: Mg-thixomolding is easily integrated into smart factories and automated production lines, allowing manufacturers to scale production while maintaining quality.

YIZUMI Magnesium Thixomolding Machine

6. YIZUMI MG Series: Built for Automotive Production

With more than 20 years of experience in the industry, YIZUMI developed China’s first magnesium thixomolding machine in 2009. In 2018, the company further expanded its capabilities by launching a large-scale injection model with a 2.5kg shot size, comparable to the maximum capacity offered globally.

Here’s how the YIZUMI MG Series Thixomolding Machine meets the demands of automotive part production:

High-Performance Injection System

This mg-thixomolding machine is engineered for speed, volume, and durability:

• - Injection piston acceleration of 200 m/s²
• - Flow rate up to 4200 L/min
• - Bladder accumulator design for fast, stable performance
• - Injection barrel made from European special steel

These specs enable high-precision molding of larger and more complex automotive parts, while keeping cycle times short and consistent.

Advanced Hot Runner Technology

YIZUMI’s hot runner system helps reduce waste and improve efficiency:

• - Saves 15%–30% in mold material usage
• - Minimizes gating and reduces scrap
• - Reduces the need for secondary processing
• - Improves interchangeability and standardization of mold components

This is especially valuable in large automotive production programs where cost efficiency and repeatability are key.

Magnesium Thixomolding machine

Intelligent Control System

The MG Series magnesium thixomolding machine includes a human-centered control interface powered by a high-speed industrial computer:

• - Fast signal response across multiple function areas
• - Accurate parameter adjustments for precision production
• - Intuitive UI for ease of operation by plant personnel

In automotive environments where uptime and consistency are non-negotiable, this control system supports both.

Optional YiCMS Monitoring System

YIZUMI also offers an Industry 4.0-ready YiCMS condition monitoring platform, enabling:

• - Remote monitoring of machine performance
• - Integration with peripheral automation equipment
• - Predictive maintenance alerts
• - Standardized digital management across production lines

For automotive OEMs and Tier 1 suppliers, this means greater transparency and process control at the factory level.

From small brackets to large structural parts, the MG Series mg-thixomolding machine supports a range of automotive applications while maintaining high performance, low cycle times, and consistent product quality.

Conclusion

Magnesium thixomolding is quickly becoming a go-to solution for manufacturers aiming to meet lightweighting targets in automotive design. Its ability to produce strong, complex parts with high precision—safely and efficiently—offers clear advantages over traditional casting methods.

With a strong technical foundation, extensive industry experience, and partnerships with professional engineering teams, YIZUMI delivers a complete thixomolding solution tailored to the needs of modern automotive manufacturing.