By Dennis Randall – Clayens
Location: Santa Maria, California
When it comes to selecting materials for manufacturing, magnesium often doesn’t make the shortlist—not because of performance shortcomings, but due to persistent myths and misinformation. At Clayens, we believe it's time to change that narrative.
Magnesium Thixomolding is revolutionizing the way manufacturers approach lightweight, high-performance metal components. Let’s take a deep dive into the most common misconceptions surrounding magnesium and explain why this material—and the Thixomolding process—deserves serious consideration.
Magnesium Thixomolding is an advanced semi-solid metal (SSM) forming process similar to plastic injection molding, but it uses magnesium alloys. The process involves heating magnesium chips into a semi-solid state and injecting them into a mold, allowing for precision casting with minimal waste, high strength, and excellent repeatability.
Thixomolding offers numerous advantages over traditional die casting, such as improved mechanical properties, better corrosion resistance, tighter tolerances, and a cleaner, more environmentally friendly process.
One of the most common fears about magnesium is its flammability. This myth usually traces back to high school science class experiments where a pure magnesium strip was set ablaze. However, those experiments used elemental magnesium—not the high-performance magnesium alloys used in modern manufacturing.
Magnesium Thixomolding uses engineered alloys that include elements like aluminum, zinc, manganese, and rare earth metals. These alloys have significantly higher ignition temperatures. A Thixomolded magnesium component must be heated above 990°F to ignite—far beyond what’s typically encountered in real-world applications.
Additionally, magnesium has excellent thermal conductivity, which helps dissipate heat quickly, making it difficult to reach combustion temperatures. In fact, in vehicle fire testing, magnesium components are often among the last materials to ignite, if at all.
Despite being the lightest structural metal, magnesium is neither exotic nor scarce. It makes up 2.7% of the Earth’s crust and is the eighth most abundant element on the planet. Sources include natural ores like magnesite and dolomite, as well as salt deposits and ocean water.
The most common industrial extraction methods—such as electrolysis from seawater—ensure a steady and reliable supply chain. Unlike some specialty metals like titanium, magnesium is far more affordable, especially when considering its performance-to-weight ratio.
This claim may have had some merit when referring to low-cost offshore magnesium casting operations. However, at Clayens, we operate state-of-the-art Thixomolding equipment in North America with highly trained technicians and rigorous quality standards.
Our magnesium parts meet or exceed the yield rates expected from precision plastic injection molding, producing net-shape, flash-free components with minimal post-processing. The result? Higher efficiency, lower rejection rates, and outstanding reliability.
Unlike traded commodities such as aluminum or zinc, magnesium is not subject to volatile market speculation. Thanks to its widespread availability and diversified sourcing—such as from the Great Salt Lake in Utah—the price of magnesium remains relatively stable.
Magnesium’s consistent pricing structure makes it an ideal material for long-term product planning and budgeting.
Magnesium’s machinability is unmatched among structural metals. It allows for faster cutting speeds, longer tool life, and lower energy consumption. The Thixomolding process creates dense, sound castings with smooth as-cast surfaces, minimizing the need for extensive machining or finishing.
For components with tight tolerance requirements, magnesium can be machined more economically than aluminum, steel, or titanium. No special tooling is required—just standard equipment and good housekeeping practices. In addition, magnesium readily accepts a wide range of surface coatings for enhanced appearance and protection.
Older magnesium die castings sometimes suffered from corrosion due to flux contamination or high impurity content. Thixomolding, however, eliminates these issues entirely.
Today’s magnesium alloys are high-purity formulations with tightly controlled levels of iron, nickel, and copper—the elements most responsible for galvanic corrosion. Manganese is added to bind trace iron, further improving resistance. As a result, modern magnesium parts often require no protective coating for general applications and perform better than standard aluminum die castings in corrosion tests.
Simple chemical treatments or conversion coatings can be applied when extra protection is needed, especially in aggressive environments like coastal or marine settings.
Magnesium Thixomolding combines the lightness of plastic, the strength of metal, and the precision of injection molding into one highly efficient manufacturing process. Magnesium parts are:
Up to 75% lighter than steel and 33% lighter than aluminum
Exceptionally strong and stiff
Ideal for EMI/RFI shielding
Highly recyclable and more environmentally friendly
Perfect for high-performance industries, including automotive, aerospace, medical, and consumer electronics
The myths surrounding magnesium are outdated and misleading. With the evolution of high-purity alloys and advanced processes like Thixomolding, magnesium has emerged as a durable, safe, and cost-effective solution for lightweight structural applications.
At Clayens, we’re proud to be industry leaders in magnesium Thixomolding. Our parts meet the highest standards of performance, precision, and reliability—making magnesium not just a viable option, but often the best option.
If you're considering magnesium Thixomolding for your next project, contact:
Randall Dennis @ 1+(805) 595-3500
Let us help you transform your design with the power of magnesium.
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