MAXImolding: Vertical Semi-Solid Magnesium Alloy Injection Molding Machine for Mega Volume Production

The four semi-solid metal casting processes Thixomolding^®, Thixocasting^®, rheocasting, and stress induced melt activation are very complex and highly maintenance intensive. The cold chamber die-casting and the hot chamber die-casting did not fulfill end user expectations for quality, energy savings, and environmental sustainability. We dedicated all our working life to solve two problems: production of high-integrity net-shape light metal parts, while reducing porosities in moldings (castings). We are fully committed to improving the current non-sustainable approach of molding, inspecting, separating, and re-melting. The Team of MAXImolding invented and patented [1‐5] a new vertically oriented, environmentally friendly Semi-Solid Metal Alloy Injection Molding Machine. The molding processing parameters are optimized without a human operator by closing a real-time X-ray feedback control loop based on the parts “quality indicators and proper AI algorithms” [2, 5]. This is an intrinsically safe, energy and material efficient, environmentally sound magnesium-molding self-learning smart factory with no emissions outside of factory parameters limits.