Appreciation Of The 2022 European Best Magnesium Die Casting Award Winning Magnesium Alloy Die Castings

1st place: Dashboard beam

Manufacturer: George Fisher Foundry Solutions, Switzerland

Dimensions (LWH): 508 mm x 300 mm x 1523 mm
Weight: 3480 grams
Alloy: AM50

Product Description: Highly loaded components, also under dynamic loads, must provide very high stiffness to eliminate vibrations, such as in the steering wheel or head-up display area. Additionally, the component must have a high degree of deformability (for example in collision behavior).

Design, casting and forming requirements: Meeting the corresponding requirements in a limited installation space means that the cross section in the casting must be designed flexibly. Stiffeners are designed to accommodate stress load variations, and simulations are used to continuously evaluate filling and solidification behavior. Integrate as many different functions as possible in the casting (connection of additional parts, integration of brackets, etc.).

Reasons for using the die-casting method: Since the installation space is very limited, die-casting offers the possibility of optimal use of the free space, thus making the structure more suitable for stress loading situations. Furthermore, the use of magnesium makes it possible to achieve high stress at low weight.

Reason for award:

- Development, design in a systematic way
- Integrate various functions
- Stiffness and NVH requirements
- Collision related parts


Second place: TKS 80 countertop

Manufacturer: Tollenbach Magnesium GmbH, Germany

Dimensions (LWH): 671 mm x 453.90 mm x 20 mm
Weight: 2260 grams
Alloy: AM60



Product description: Produced on a Frech DAK1600 production cell / Large area thin-walled parts (3mm wall thickness) meet extreme flatness requirements of 0.5mm over the entire surface and are 100% inspected in mass production with 21 measuring points.

Design, casting and molding requirements: very high surface requirements - powder coating of complete visible area.

Reason for using the die casting method: By achieving the required flatness of 0.5mm over the entire part, complex straightening processes are no longer required. Competitors on the market are using this straightening process, and by contrast, the precision is not as good as that of die-cast sheets. Lightweight - Compared with aluminum die casting, the weight is reduced by more than 1.2 kg.

Reason for award:

- High quality surface treatment in as-cast condition
- For large-area thin-walled parts with a wall thickness of only 3 mm, the flatness of the entire surface is required to be 0.5 mm

Third Place: Cone Bracket EE0043-30-2020

Manufacturer: Dynaxter (Germany) GmbH, Germany

Dimensions (LWH): 47.5 mm x 47.5 mm x 39 mm
Weight: 32.05 grams
Alloy: AZ91D

Product description: This part is used in coffee grinders in the catering industry. The coffee beans are ground with the help of the cone holder.

Design, casting and molding requirements: excellent casting quality, fully filled interior, ventilation, strength, weight.

Reason for the die casting method: A plastic part was replaced. Compared to plastic tools, the mold life is 4 times longer. Higher strength and precision. Parts can be used without machining. The system runs faultlessly at the end user.

Reason for award:

- Replaces plastic parts
- Achieved 4 times longer die life
- Higher strength and precision
- No machining required