Our Magnesium Die Casting Services
At Yigu Technology, our Magnesium Die Casting solutions redefine lightweight manufacturing without compromising strength. Leveraging decades of expertise, advanced technology, and strict quality control, we transform high-performance magnesium alloys into dimensionally stable components for automotive, aerospace, and electronics industries. Whether you need high volume production runs or custom-designed parts, we deliver cost-effective, reliable results—backed by fast turnaround and comprehensive customer support.
What Is Magnesium Die Casting?
Magnesium Die Casting is a specialized metal casting process that uses high pressure to force molten magnesium into a steel mold (die), producing ultra-light, high-precision parts. As an innovative die casting method, it capitalizes on magnesium’s unique properties—low density, excellent strength-to-weight ratio, and good castability—to meet the demands of weight-sensitive industries.
A clear process overview highlights its efficiency: Molten magnesium (heated to 650–675°C) is injected into a closed die at high pressure (40–120 MPa). The metal cools and solidifies rapidly, then the die opens to eject the finished part. Table 1 compares magnesium die casting to other common die casting metals:
| Die Casting Type | Metal Used | Density (g/cm³) | Key Benefit | Ideal Use Case |
| Magnesium Die Casting | Magnesium Alloys | 1.8 | Ultra-light, high strength-to-weight ratio | Aerospace components, electronics housings |
| Aluminum Die Casting | Aluminum Alloys | 2.7 | Balanced weight + cost | Automotive structural parts |
| Zinc Die Casting | Zinc Alloys | 6.6 | Low cost, small part precision | Hardware, consumer goods |
Yigu Technology’s Magnesium Die Casting Capabilities
Our Magnesium Die Casting capabilities are engineered to handle the most demanding projects, from lightweight electronics parts to high-strength aerospace components.
Key Capabilities Breakdown
| Capability Area | Details |
| Capacity | 80,000–500,000 units/month (optimized for high-volume automotive/electronics parts) |
| Expertise | 15+ years of experience in magnesium die casting, with specialized knowledge in alloy selection and process optimization |
| Customization | Tailored mold design, alloy blending, and surface treatment for unique project needs |
| Technology | 20+ automated die casting machines (150–1,000 tons clamping force) with real-time process monitoring |
| Quality Control | ISO 9001 & IATF 16949 certified; 100% inspection (dimensional, porosity, surface finish) |
The Magnesium Die Casting Process
The die casting process for magnesium follows a structured workflow optimized for speed and precision, leveraging magnesium’s unique thermal properties.
- Preparation: The steel die is preheated (180–250°C) and coated with a lubricant to prevent metal sticking and ensure smooth ejection.
- Injection: Molten magnesium alloy is injected into the die cavity at high speed (2–6 m/s) and pressure (40–120 MPa), ensuring full filling of complex geometries.
- Cooling: The metal solidifies rapidly (10–25 seconds) in the die, maintaining dimensional accuracy while pressure is held to reduce porosity.
- Ejection: The die opens, and ejector pins push the finished part out—magnesium’s low shrinkage rate (0.8–1.2%) ensures the part retains its shape.
- Post-Processing: Excess material (flash) is trimmed, and parts undergo optional machining or surface treatment to meet final specs.
- Automation: Robotic arms handle injection, ejection, and post-processing steps, reducing human error and increasing production efficiency by 30%.
On average, the total cycle time for a medium-sized magnesium part (e.g., a laptop frame) ranges from 15–30 seconds.
Materials Used in Magnesium Die Casting
Choosing the right magnesium alloys is critical for part performance, and we offer expert alloy selection support to match your project’s requirements.
Magnesium Alloy Properties & Applications
| Alloy Type | Common Grades | Key Material Properties | Typical Applications |
| AZ Series | AZ91D, AZ31B | Good strength (240–280 MPa), excellent castability, cost-effective | Automotive parts (steering wheels, transmission housings), electronics housings |
| AM Series | AM60B, AM50A | Higher ductility than AZ series, good impact resistance | Structural components (aerospace brackets, consumer goods frames) |
| AE Series | AE44 | High heat resistance (up to 150°C), good corrosion resistance | Engine components, high-temperature industrial parts |
| Custom Alloys | Blended to specs | Tailored for enhanced corrosion resistance or strength | Medical devices, marine components |
All our magnesium alloys undergo rigorous testing for corrosion resistance (via salt spray testing) and mechanical properties to ensure consistency.
Surface Treatment for Magnesium Die Cast Components
Surface finishing is essential for magnesium parts, as it enhances corrosion resistance (a key consideration for magnesium) and improves aesthetics.
| Treatment Method | Purpose | Advantages | Ideal For |
| Anodizing | Creates a hard, protective oxide layer | Excellent corrosion resistance, customizable colors (clear, black) | Automotive exterior parts, aerospace components |
| Powder Coating | Applies a durable polymer finish | Chip-resistant, UV-stable, wide color range | Outdoor equipment, consumer goods |
| Plating | Adds a metal layer (e.g., nickel, chrome) | Improves conductivity, decorative appeal | Electrical connectors, medical devices |
| Painting | Enhances aesthetics and basic protection | Fast application, low cost | Non-critical structural parts, consumer goods |
| Coating | Applies a specialized protective layer (e.g., ceramic) | Superior corrosion resistance, heat tolerance | High-temperature parts, marine components |
| Surface Quality Optimization | Polishing, deburring | Smooth finish, removes minor defects | High-end electronics, luxury goods |
Tolerances in Magnesium Die Casting
Dimensional accuracy is a strength of magnesium die casting, with tight tolerances achievable through precision mold design and advanced process control. We adhere to strict quality standards to meet even the most demanding specs.
Typical Tolerance Ranges for Magnesium Die Casting
| Part Feature | Standard Tolerance | Tight Tolerance (Custom) | Tolerance Levels Reference |
| Part Dimensions (≤100mm) | ±0.1mm | ±0.05mm | ISO 8062:2018 Class CT6 |
| Hole Positioning | ±0.15mm | ±0.08mm | DIN EN 13920 |
| Flatness | 0.1mm/m | 0.06mm/m | IATF 16949 |
Machining tolerances are further refined via CNC machining for critical features, ensuring parts fit seamlessly into assemblies.
Advantages of Magnesium Die Casting
The advantages of Magnesium Die Casting make it the top choice for weight-sensitive, high-performance applications.
- Lightweight: Magnesium is 33% lighter than aluminum and 77% lighter than steel, reducing overall product weight—critical for EVs (improving range) and aerospace (lowering fuel consumption).
- High Strength: Even standard AZ91D alloy offers tensile strength up to 280 MPa, suitable for structural parts like automotive steering wheels.
- Dimensional Stability: Low shrinkage rate (0.8–1.2%) ensures consistent part geometry, reducing the need for secondary machining.
- Cost-Effective: For high-volume production, magnesium die casting’s fast cycle times and low material waste (typically <5%) lower per-unit costs vs. other lightweight metals.
- Design Flexibility: Magnesium flows easily into complex molds, enabling intricate features (thin walls down to 0.8mm, small holes) without defects.
- Recyclability: Magnesium is 100% recyclable, with recycling requiring 90% less energy than producing primary magnesium—supporting sustainability goals.
Energy Efficiency: Lightweight magnesium parts reduce energy consumption in end products (e.g., EVs use 10–15% less energy with magnesium components).
Industry Applications of Magnesium Die Casting
Magnesium Die Casting applications span diverse industries, thanks to its ultra-light weight, strength, and precision.
| Industry | Key Applications | Alloy of Choice | Why Magnesium Die Casting? |
| Automotive | EV battery frames, steering wheels, transmission cases, engine components | AZ91D, AE44 | Lightweight (improves range), high strength |
| Aerospace | Interior structural parts, satellite components, drone frames | AM60B, AZ31B | Ultra-light, dimensional stability |
| Electronics | Laptop frames, smartphone housings, 5G base station parts | AZ91D, AM50A | Lightweight, good thermal conductivity |
| Consumer Goods | Power tool housings, camera bodies, sporting goods (e.g., bicycle components) | AZ91D | Durable, lightweight, sleek finish |
| Medical Devices | Wheelchair frames, diagnostic equipment housings (non-implant) | AZ91D (medical-grade) | Lightweight for portability, corrosion-resistant (with treatment) |
| Telecommunications | Antenna housings, router chassis | AZ91D | Lightweight, weather-resistant (with coating) |
Manufacturing Techniques for Magnesium Die Casting
Our casting techniques combine proven methods with innovation to deliver consistent, high-quality magnesium parts.
- High-Pressure Die Casting: The primary method for magnesium (90% of our projects), it uses high pressure to ensure full mold filling and reduce porosity—ideal for complex parts.
- Low-Pressure Die Casting: Used for large, thick-walled parts (e.g., EV battery frames), it minimizes turbulence and ensures uniform metal flow.
- Gravity Die Casting: Employed for small-batch, high-strength parts (e.g., aerospace brackets), it uses gravity to fill the mold—suitable for alloys with high melting points.
- Tooling: We use H13 hot-work steel for molds, engineered to withstand magnesium’s melting point and repeated use (150,000+ cycles). Mold cooling channels are optimized to reduce cycle time.
- Molding: Custom molds are designed using CAD/CAM software, with 3D prototyping available to test designs before full production—reducing lead times by 20%.
Process Optimization: AI-powered sensors monitor temperature, pressure, and injection speed in real time, adjusting parameters to minimize defects like porosity.
Case Studies: Yigu Technology’s Magnesium Die Casting Success Stories
Our case studies showcase how we solve real-world challenges for clients using magnesium die casting.
Case Study 1: Automotive EV Battery Frame
- Challenge: A leading EV manufacturer needed 100,000 lightweight battery frames monthly, with tight tolerances (±0.08mm) and corrosion resistance for outdoor use.
- Solution: Used AZ91D magnesium alloy with anodizing surface treatment. Implemented high-pressure die casting and automated quality inspection.
- Result: Frames were 30% lighter than aluminum alternatives, achieved 99.7% defect-free rate, and met IATF 16949 standards—helping the client improve EV range by 12%.
Case Study 2: Electronics Laptop Frame
- Challenge: A tech firm required ultra-light laptop frames with a sleek finish and good thermal conductivity.
- Solution: Utilized AM60B magnesium alloy and added powder coating for aesthetics. Designed custom molds to integrate heat dissipation channels, eliminating secondary machining.
Result: Frames weighed 25% less than plastic-aluminum blends, withstood 10,000+ opening/closing cycles, and improved laptop thermal performance by 15%.
Why Choose Us for Magnesium Die Casting?
When you partner with Yigu Technology for Magnesium Die Casting, you gain a trusted collaborator focused on your success. Here’s why clients choose us:
- Quality: We adhere to strict quality standards (ISO 9001, IATF 16949), with rigorous testing at every stage—from raw material inspection to final part approval.
- Reliability: We maintain 98% on-time delivery rates, thanks to our scalable capacity and proactive supply chain management.
- Customer Service: A dedicated account manager provides 24/7 support, from design consultation to post-delivery follow-up—ensuring your project stays on track.
- Innovation: We invest 15% of annual revenue in R&D to develop new techniques (e.g., AI process control) that improve quality and reduce costs.
- Cost Savings: Our automated processes and material efficiency reduce per-unit costs by 15–25% vs. competitors.
- Fast Turnaround: We deliver prototypes in as little as 5 days and full production runs in 2–4 weeks—faster than industry averages.
Comprehensive Solutions: We offer end-to-end services, from design optimization to surface treatment—eliminating the need for multiple suppliers.