Magnesium Alloy Die Casting Services

Marcus supports magnesium alloy die casting as part of a broader end-to-end manufacturing solution that includes in-house tool room support, CNC machining, surface finishing, assembly, and structured new product development. This allows customers to source cast and finished magnesium components through one supplier, improving coordination, quality control, and lead-time management across the full production cycle.

Magnesium alloys are commonly produced using cold chamber die casting because the process is well suited to metals with higher operating temperatures than zinc. In this method, molten metal is transferred from a separate furnace into the shot chamber and injected into the die under high pressure. This supports strong dimensional repeatability, efficient cycle times, and suitability for structural or precision components.

Magnesium alloy die castings are widely used in automotive, EV, aerospace, electronics, healthcare, energy, and industrial manufacturing applications. These sectors value magnesium for its lightweight properties and ability to support complex geometries. Marcus serves global customers across these industries and can support programmes that require casting, machining, finishing, inspection, and assembly under certified manufacturing controls.

Yes. Marcus operates more than 20 in-house CNC machining centres, including 3, 4, and 5 axis equipment, to machine critical features on die cast components. This includes bearing bores, threaded interfaces, sealing surfaces, and mating faces. In-house machining improves dimensional control, reduces handoff delays between suppliers, and helps maintain consistency from casting through final inspection.

Yes. Marcus has an in-house tool room that manages tool design, fabrication, maintenance, repair, engineering changes, and trial validation. The team uses CAD/CAM integration, DFM review, and process simulation before tooling is machined, followed by T0 and T1 trials in-house. This helps identify manufacturability issues early and supports smoother transition from development into stable production.

Marcus operates under IATF 16949:2016 and ISO 9001 certified processes, supported by structured quality methods such as APQP, PPAP, FAIR, inline inspection, and advanced metrology. Inspection resources include CMM and other validation tools used to confirm dimensional and process requirements. These systems are designed to support repeatable quality for OEM and industrial programmes with demanding documentation and traceability expectations.

Yes. Marcus can deliver magnesium components as cast, machined, surface treated, or assembled depending on programme requirements. With in-house finishing and assembly support, customers can receive parts that are closer to installation-ready rather than managing multiple outside vendors. This single-source approach helps simplify procurement, reduce logistics complexity, and improve accountability across the manufacturing process.

Marcus uses a structured new product development framework that includes DFM collaboration, simulation-led defect analysis, material and process input, rapid prototyping, trial runs, and production validation. T0 and T1 trials are completed before scale-up, and APQP and PPAP processes can be applied where required. This approach helps reduce development risk and improves readiness for serial production.