Leggera Technologies Publishes Guide Comparing Thixomolding and Die Casting

HOLLY, MI, UNITED STATES, October 29, 2026 /CourierPR/ -- Leggera Technologies, a magnesium thixomolding manufacturer based in Holly and Orion Township, Michigan, has published a comprehensive guide comparing thixomolding and die casting processes for magnesium parts. The guide, available for free download at leggeratech.com/thixomolding-vs-die-casting/, provides engineers with a detailed side-by-side comparison of the two processes, focusing on key factors such as porosity, wall thickness, tool life, and cost.

According to the guide, thixomolded parts exhibit significantly lower porosity compared to die cast parts. Specifically, thixomolded parts show porosity that is 50 percent lower than die cast parts. A 2025 review in the Journal of Magnesium and Alloys further supports this claim, stating that thixomolded porosity is under 1.5 percent, while a 2024 study of hot-chamber die-cast AM60 reports a porosity range of 1.5 to 4 percent.

In terms of wall thickness, the guide highlights that thixomolded walls can be as thin as 0.5 millimeters, compared to 1 to 1.5 millimeters for die-cast magnesium parts. This difference in wall thickness is significant for thin-wall structural parts, as halving the wall thickness can reduce the metal content in that section by half, leading to substantial weight savings.

While thixomolding offers these advantages, the guide also notes that die casting remains a faster and cheaper option for small, simple, and high-volume parts. Cold-chamber die-casting cycles typically take around one minute, whereas Leggera’s thixomolding process takes 70 to 90 seconds.

Thomas Kowal, CEO of Leggera Technologies, emphasized the importance of this guide for engineers.

Founded in 2014 by Nathan Sanko and Tom Darnell, Leggera Technologies is known for its large, thin-wall structural magnesium parts for automotive OEMs and Tier 1 suppliers. The company’s Orion Township molding operation is IATF 16949 certified, and it operates some of the world’s largest magnesium thixomolding machines. Leggera also offers magnesium machining, extrusion, powder coating, assembly, and part design engineering.

The guide and its two-page comparison sheet are free to download at leggeratech.com/thixomolding-vs-die-casting/, with no sign-up required. A companion page on the company’s website explains the magnesium thixomolding process step by step, from the alloy chips in the hopper to the finished, powder-coated part.