At this year’s Plastpol trade fair, BOLE Europe Technology will present thixomolding technology in Europe for the first time together with the premiere of the new BOLE MG 300 machine featuring a 300-ton clamping force. This is expected to be one of the key highlights of this year’s exhibition for the plastics processing and lightweight materials industries.
Developed by BOLE in cooperation with scientific research institutions, thixomolding technology represents an advanced method for processing magnesium alloys in a semi-solid state. The process is increasingly recognized as one of the most promising technologies for the automotive, consumer electronics, and lightweight manufacturing sectors.
Magnesium Injection Molding – Metal Processed Like Plastic
Thixomolding can be described as a combination of die casting and plastic injection molding technology. Unlike conventional casting processes, the material is not processed in a fully molten state. Magnesium alloy chips are fed into the machine barrel, transformed into a semi-solid state, and then injected into the mold at very high speed.
A key element of the process is the thixotropic behavior of the material – under shear stress, the alloy flows like a liquid while maintaining the characteristics of a semi-solid material. Thanks to the specially designed plasticizing system, it is possible to achieve a fine-grained, globular microstructure with a high degree of uniformity.
BOLE began developing thixomolding technology in 2019 through a joint research and development program with Shanghai Jiao Tong University under the leadership of Professor Xiaoqin Zeng.
BOLE MG 300 – European Premiere at Plastpol
The centerpiece of BOLE’s Plastpol presentation will be the premiere of the new MG 300 injection molding machine with a 300-ton clamping force, designed specifically for semi-solid magnesium alloy processing.
The new platform has been engineered to deliver high process dynamics and stable production parameters. The machine design incorporates:
- a high-rigidity clamping unit,
- a low-inertia injection system,
- high-response servo valves,
- a mechanical-hydraulic braking system for high-speed injection.
The technology enables extremely high injection speeds while maintaining excellent process precision and control over the material’s microstructure.
According to BOLE, the solution has been developed for the production of thin-wall and high-strength components for:
- e-mobility,
- consumer electronics,
- aerospace,
- drones and lightweight engineering applications.
An Alternative to Conventional Magnesium Die Casting
One of the greatest advantages of thixomolding technology is its ability to eliminate many of the issues associated with traditional magnesium die casting.
The process does not require a separate melting furnace or protective gases such as SF₆, which are facing increasing environmental restrictions within the European Union. The technology also reduces fire risk and can lower energy consumption by up to 50–60% compared to conventional casting processes.
Additional benefits include:
- lower porosity,
- a more homogeneous microstructure,
- higher mechanical strength,
- improved fatigue resistance,
- extended mold life,
- reduced material losses.
According to data presented by BOLE, component strength can increase by approximately 10%, while elongation may improve by as much as 50% compared to traditional casting technologies.
Lightweight Manufacturing and New Design Possibilities
BOLE emphasizes that the development of thixomolding technology is a direct response to the growing importance of lightweight materials and component weight reduction in modern industry.
The company has already demonstrated a wide range of semi-solid magnesium applications, including:
- laptop housings,
- consumer electronics components,
- automotive structural parts,
- UAV components,
- and even the world’s first semi-solid magnesium automotive wheel hub.
Industry experts believe that the technology could play a significant role in the future development of e-mobility and advanced lightweight structures.
BOLE at Plastpol
During Plastpol, visitors to the BOLE booth will have the opportunity to learn more about the capabilities of thixomolding technology and discuss potential industrial applications of the new MG 300 platform with the company’s technical experts.
