Magnesium – Making Lightweight Parts a Reality

Magnesium - The Future of Lightweight Parts

Global industry is under more pressure than ever to to reduce product weight more than ever before.  Most engineers lean to plastics or aluminums - but have you considered MAGNESIUM?

Magnesium is 30% lighter than aluminum and twice the strength at the same thickness, while at the same time achieving cost parity with Aluminum. Magnesium has been used for years in automotive seat frames, housings, power tools, and laptops, it is not new it is just coming into the fold with the push for lower weight designs.

OEMs are choosing Magnesium to meet these challenges for components and assemblies. Magnesium has been used for years in automotive applications such as steering wheels, brackets, convertible top structural components, and seat frames, and is gaining significant momentum for other components.

Magnesium’s mechanical properties are quite similar to Aluminum, allowing engineers to modify existing designs to achieve significant weight reductions and strengthening. GTI offers full technical design services to assist in-house engineering in part design and tool optimization.
There are three ways to manufacture Magnesium parts:  Thixomolding, Die Casting, or Machining.  We can help with all there.

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Lighter | Better | Stronger

Thixomolding Magnesium provides the flexibility of plastic injection molding with the strength of die casting, resulting in stronger parts with complex shapes and part consolidation opportunities.

  • 2x longer tool life than aluminum die casting = 200% ROI increase
  • Complex geometries
  • Cost effective
  • Numerous Coating Options – both decorative and protective
  • Excellent machinability

Material Comparison








Density (psi) 0.0653 0.0989 0.284
Modulus (ksi) 6,500 10,500 29,000
TYS (psi) 23,000 23,000 45,000
10 Day Salt Spray (mils/year) 4 13 30


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Molding Options

Outside of straight machining, magnesium offers two molding options: High Pressure Die Casting and Thixomolding. Each process has its advantages, however which process to design for depends on a variety of technical, commercial, and program factors.

GTI advises our clients on which process is the most suitable for each part, including supply chain.

magnesium die casting

Don't Do It On Your Own!

GTI works with the entire program team to evaluate options and minimize risk in the design process and in the supply chain.

On average 75% of an engineered component’s cost is incurred during the early phases of design.    GTI Manufacturing works closely with its client’s program management, industrial designers, mechanical engineers, and procurement staff. We provide Advanced Manufacturing Engineering, Design Guidance, Supply Chain Development and Full Life Cycle management.

Our comprehensive Technical and Commercial Analysis provides our partners with the lowest costs and highest yielding components.

Let us help you fine tune the remaining 25% and bring you parts with success.