Lightweight, thin-walled, strong metal parts

thixomolding power tool impellerThixomolding is a unique process that allows manufacturers to design highly complex, light weight parts from magnesium alloys for medium to high volume applications.

Many people confuse Thixomolding and Metal Injection Molding (MIM) which is is certainly understandable; however, the processes are completely different and used in different applications.  Thixomolding is high-pressure injection molding of a semi-molten magnesium alloy and MIM is a powdered/sintered metal process.

Thixomolding injects a magnesium alloy slurry at extremely high velocities into a mold that reduces voids.  A properly designed part will have very high yields, excellent part detail, superb metallurgical structure, and tight tolerance capability when compared to magnesium die casting.

The concepts and theories behind designing parts for Thixomolding are more similar to plastic injection molding rather than die-casting.  In fact if you are familiar with plastic injection molding you are about 80% of the way to designing Thixomolded parts.  We recommend that our customers design their parts for plastic injection molding and then let GTI help you optimize the final Thixomolding design.

Thixomolding Advantages

  • Dimensional Precision
  • Thin Wall Capability (>0.040")
  • Lightweight
  • Complex Net Shapes
  • Excellent, Cosmetic Surface Finish
  • Reduced Secondary Operations
  • Low Porosity
  • High Volume
  • Variety of Finishes Available
  • Competitive Pricing
  • Global Supply Chain
  • EMI/RFI Shielding
  • Excellent machinability 

Industries using Thixomolding


  • Lighting, interior and exterior
  • Interior components
  • Frames
  • Housings

Computer Peripherals
Consumer Electronics
Medical Devices

  • Handheld devices
  • Missiles
  • Aircraft components
  • Firearms


vs. Injection Molding

  • 10-20x Stiffer
  • Dramatically Stronger
  • Similar Part Complexities & Geometries
  • Potentially Lighter Parts
  • Elimination of EMI/RFI Shielding Operations
  • Part Consolidation

vs. Die Casting

  • Lower Costs
  • >30% Lighter than Al
  • >50% Lighter than Zn
  • Reduction and/or Elimination of Secondary Operations
  • Lower Overall Tooling Costs
  • Thinner Walls
  • Better Metallurgical Properties
  • Part Consolidation
  • Superior Corrosion Resistance

Want to Learn More

GTI can answer your questions and help you determine the best option for your project