Custom Magnesium Die Casting Services
End-to-end magnesium die casting solutions for lightweight structural parts. From tooling design and high-pressure casting to CNC machining and finishing, we deliver precision magnesium components with stable quality, tight tolerances, and fast production support for automotive, electronics, bicycle, and aerospace industries.
- Expert Engineering Support
- Cost-effective Solutions
- Transparent Quotations
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Magnesium Die Casting Factory & Manufacturing Capability
ZH Precision operates a magnesium die casting facility equipped with advanced die casting equipment and high-pressure casting systems, supporting standardized production of complex magnesium alloy components. Our in-house manufacturing capability and process control ensure stable dimensional accuracy, consistent output and repeatable batch quality. All magnesium die cast parts undergo full inspection to ensure reliable performance for industrial applications.
Magnesium Die Casting with ZH Precision
ZH Precision delivers custom magnesium die casting services. In-house capabilities include mold design, high-pressure casting, CNC machining, and surface finishing. Prototype and mass production are both supported with stable process control and consistent output.
A full range of magnesium alloy components is manufactured. This includes structural housings, equipment frames, mounting brackets, and thin-wall complex parts. Components provide lightweight structure, stable dimensional performance, and consistent mechanical properties for industrial applications.
Magnesium Die Casting Machining & Finishing
Secondary Processing
Gate removal, flash trimming, and deburring ensure clean and precise cast surfaces for further machining.
CNC Precision Machining
CNC milling, turning, drilling, tapping, and grinding achieve tight tolerances and functional geometries.
Surface Treatment
Finishing options such as polishing, coating, conversion coating, and painting improve corrosion resistance.
Quality Inspection
Parts are inspected to specification requirements, ensuring dimensional accuracy and surface quality
Magnesium Die Casting Custom Capabilities
We provide custom magnesium die casting solutions with stable manufacturing capabilities and controlled engineering processes. With standardized production practices and strict process management, we deliver high-precision lightweight magnesium components supporting prototype development and scalable production programs.
| Description | Typical Capability |
|---|---|
| Maximum Part Weight | Up to 2.5 kg (depending on geometry) |
| Minimum Part Weight | From 0.01 kg |
| Part Size Range | 8 × 5 × 3 mm to 650 × 480 × 150 mm |
| Wall Thickness | 0.6 – 8 mm (process dependent) |
| Dimensional Tolerance | ±0.05 – ±0.12 mm (feature dependent) |
| Sample Lead Time | 4–6 working days |
| Mass Production Lead Time | 28–35 working days |
| Shipping | Worldwide shipping available |
Free Magnesium Die Casting Consultation
Share your design files, and we will provide optimized DFM solutions, competitive pricing and professional mass production suggestions.
Magnesium Die Cast Laptop Palm Rest
Control Focus:
This magnesium die cast laptop palm rest was developed for our client, replacing their previous multi-part aluminum-plastic assembly. The core focus was on achieving a uniform wall thickness of just 0.8 mm while maintaining exceptional rigidity, significantly reducing component weight to support the client’s lightweight product goals. Critical dimensions are held to ±0.05 mm tolerance to ensure seamless fit and reliable assembly.
Process Technology:
Manufactured from AZ91D magnesium alloy via high-pressure die casting, followed by premium multi-step finishing including sandblasting, passivation, and painting. The final part delivers a durable, fingerprint-resistant matte appearance. By delivering a monolithic magnesium solution, we helped the client simplify their assembly process, improve structural integrity, and meet their high-volume production and quality requirements.
Magnesium Die Casting Materials
A range of magnesium die casting alloys including AZ91D, AM60B, AM50, as well as high-temperature AE and MRI series. These materials are selected based on ASTM-related requirements and industrial standards, balancing castability, strength, ductility, and high-temperature performance for automotive, 3C, and industrial applications.
AZ91D
Most widely used magnesium die casting alloy, offering a balanced strength-to-weight ratio, excellent corrosion resistance, and good castability. It is commonly used for structural housings, mechanical components, and electronic enclosures.
| Tensile Strength | Yield Strength | Elongation | Hardness | Density | Corrosion Resistance | Castability |
|---|---|---|---|---|---|---|
| 230 MPa | 160 MPa | 3.0 % | 70 HB | 1.81 g/cm³ | Good | Excellent |
AM60B
High-ductility magnesium alloy with strong impact resistance and energy absorption performance. It is widely used in automotive safety components such as seat frames and instrument panel structures.
| Tensile Strength | Yield Strength | Elongation | Hardness | Density | Corrosion Resistance | Casting |
|---|---|---|---|---|---|---|
| 225 MPa | 130 MPa | 8.0 % | 65 HB | 1.79 g/cm³ | Moderate | Very Good |
AM50
Magnesium alloy with lower aluminum content, providing improved ductility and elongation at the expense of slightly reduced strength and castability. It is suitable for applications requiring higher deformation tolerance.
| Tensile Strength | Yield Strength | Elongation | Hardness | Density | Corrosion Resistance | Casting |
|---|---|---|---|---|---|---|
| 210 MPa | 115 MPa | 10.0 % | 60 HB | 1.78 g/cm³ | Moderate | Good |
High-Temperature Magnesium Alloys (AE / MRI Series)
Special magnesium alloys designed for elevated temperature environments above 120°C. These materials provide improved creep resistance, maintaining structural stability, bolt tension, and sealing performance under thermal load.
Surface Finishes for Magnesium Die Casting Parts
Magnesium requires proper surface protection due to its reactivity. We provide a range of tailored finishing options, including sandblasting, polishing, chemical conversion coating, passivation, painting, and anodizing, to enhance corrosion resistance, surface durability, and appearance quality.
Deburring
Deburring removes flash and sharp edges to improve part fit, safety and surface consistency.
Electroplating
Electroplating improves corrosion resistance, wear performance and decorative appearance for zinc parts.
Sand Blasting
Sand blasting creates a uniform matte texture while preparing surfaces for coating adhesion.
Tumbling
Tumbling smooths edges and removes burrs to improve surface consistency and part appearance.
Brushed Finish
Brushed finishing creates linear metal textures while reducing the visibility of surface marks.
Polishing
Polishing enhances surface smoothness and appearance for decorative and precision zinc components.
Chromate Conversion
Chromate conversion improves corrosion protection while enhancing adhesion for painting and coating.
Powder Coating
Powder coating provides durable protection with strong wear resistance and lasting surface performance.
What is Magnesium Die Casting？
Magnesium die casting is a high-pressure manufacturing process in which molten magnesium alloy is injected into a steel mold to produce lightweight and complex metal components. The process relies on precise control of pressure, injection speed, and temperature to ensure accurate and consistent part formation.
Compared with aluminum die casting, magnesium alloys solidify faster, enabling shorter cycle times and lighter components with good dimensional stability. However, due to their high reactivity, strict control of melting, pouring, and temperature management is required to ensure safe and stable production.
When to Choose Magnesium Die Casting
Magnesium die casting is an ideal solution when lightweight design is a key requirement without compromising structural performance. It is widely used in applications where reducing weight improves efficiency, portability, or overall system performance, such as automotive components, electronic enclosures, and consumer devices.
It is also well-suited for high-volume production of complex, thin-walled parts that require stable dimensions and consistent quality. With fast cycle times and excellent repeatability, magnesium die casting supports efficient mass manufacturing. However, for high-temperature operating environments, material selection should be carefully evaluated or upgraded to heat-resistant magnesium alloys.
Advantages of Magnesium Die Casting
1.Lightweight Structure: Enables significant weight reduction compared to aluminum and steel, improving overall product efficiency.
2.Energy Efficiency: Lower melting temperature reduces energy consumption during the casting process.
3.Complex Geometry Capability: Suitable for manufacturing intricate shapes and integrated structures in a single process.
4.High Production Efficiency: Fast solidification supports shorter cycle times and efficient large-scale manufacturing.
5.Good Mechanical Performance: Provides sufficient strength and stiffness for structural and functional applications
6.Excellent Machinability: Allows easy secondary processing such as CNC machining and surface finishing.
7.Stable Manufacturing Process: Supports consistent quality output under controlled high-pressure die casting conditions.
Frequently Asked Questions
A: Magnesium die casting is widely adopted for high-volume manufacturing where weight reduction and structural integration are prioritized. With well-controlled hot-chamber or cold-chamber die casting processes, it delivers stable repeatability and consistent dimensional accuracy. The final feasibility depends on part geometry, tolerance standards and annual production volume.
A: Typical quality risks are porosity, shrinkage cavity and gas entrapment, which are more prominent in complex thin-wall components. These defects can be minimized via optimized gating and runner design, stabilized process parameters and in-line quality inspection. Early DFM evaluation is essential to lower defect rates and boost production yield.
A: Magnesium die casting helps cut overall expenditure by integrating multiple parts into one and simplifying subsequent machining and assembly processes. Nevertheless, magnesium raw material cost is higher than aluminum alloy. Overall cost-effectiveness relies heavily on design optimization, mass production scale and secondary processing scope.
A: Critical design constraints cover uniform wall thickness, sufficient draft angles, reasonable rib layout and controlled flow length. Improper design will raise porosity risks and weaken structural mechanical performance. It is strongly advised to complete DFM manufacturability review prior to mold fabrication.
A: Yes. With precision mold tooling, mature process control and complete quality inspection systems, magnesium die casting can maintain reliable dimensional stability and stable mechanical properties, fully meeting strict specification demands in mass production.