Thixomolding !link! — Original & Best

| Limitation | Description | |------------|-------------| | Material Scope | Primarily magnesium; aluminum thixomolding is challenging (oxide skin, narrower semi-solid window). | | Part Size | Currently limited to ~2 kg (largest commercial machines: ~800–1200 ton clamping force). | | Feedstock Cost | Pre-alloyed, clean chips cost more than ingots for die casting. | | Equipment Cost | High capital investment (machine cost comparable to high-end die casting cells). | | Cycle Time | Slightly longer than die casting (due to slower injection speeds). | | Process Control | Requires precise temperature and shear rate control to maintain stable solid fraction. |

Thixomolding combines the principles of plastics injection molding and metal die casting. It exploits the behavior of certain alloys: when a semi-solid slurry is sheared, its viscosity drops dramatically, allowing it to flow like a liquid. When shearing stops, it solidifies. thixomolding