Proto Labs Inc., Maple Plain, Minn., has introduced magnesium injection molding into its current rapid manufacturing services. This advanced injection molding process, known as thixomolding, enables product designers and engineers to prototype with the same materials and processes as the final production part. In addition to prototypes, Proto Labs offers production parts in quantities up to 5000+, with a typical turnaround time of 15 days.
Magnesium injection molding is a process of manufacturing fully dense, net-shape magnesium parts, similar to those produced in die casting, using an injection molding press. Referred to also as thixomolding, the process involves heating chipped magnesium feedstock in the barrel of a press. A reciprocating screw works the material into a thixotropic (gel-like) state, and the material is forced into a steel mold at high speed and pressure to create the part. Magnesium injection molding is a mature, established manufacturing process that produces strong, lightweight magnesium parts that maintain detailed features and thin walls.
Magnesium is a strong and lightweight metal that is increasingly being used in the automotive and aerospace industries to reduce weight. “In recent years, lightweighting has become a significant factor in automotive product development, for example, as engineers are being tasked with drastically reducing vehicle weight in order to improve vehicle gas mileage,” says Becky Cater, Proto Labs’ engineer and product manager. “We see magnesium injection molding as an important tool for achieving this.”
Magnesium AZ-91D joins Proto Labs’ current injection molding offerings that include more than a hundred thermoplastic, liquid silicone rubber, steel, and stainless steel materials.
The company uses advanced 3D printing, CNC machining, and injection molding technologies to produce parts within days. The result is an unprecedented speed-to-market value for product designers and engineers worldwide.
www.protolabs.com
