Decarbonise your magnesium foundry with MAXImolding!
The most economical and advanced semi-solid process.
About magnesium forming.
Any part size and shape.
On an ultra lean casting cell.
Our Mission
By bringing the melt to a semi-solid thixotropic state, a magnesium alloy foundry can use minimal energy to produce a slurry for casting high integrity net-shape parts.
1% of global CO2eq. emissions are caused by light metal foundries heat. Germany’s output alone is about 1,2 million tons CO2eq. per year.
No carbon neutral, carbon free, cost-competitive and easy to integrate solution exists. Why melt at 660°C when semi-solid magnesium can be cast at 540°C?
Our Method
The transition from a fully liquid magnesium melt to a semi-solid thixotropic melt is our method of decarbonisation. This allows us to operate at a lower temperature between the solidus and liquidus using minimal energy. From cold chips to a semi-solid slurry on demand by the addition of heat only, in a totally enclosed process, to net shape parts.
MAXImolding works in the semi-solid temperature range between 480 and 580°C for the AZ91 alloy. The microstructure of the alloy has spherical, non-dendritic features with 50% solids (Dr. Frank Czerwinski). This avoids the formation of defects.
The process of decarbonising a magnesium alloy foundry involves four key steps:
1) Adopting energy efficient practices: adopting more energy efficient practices is critical. This can include switching to more efficient machinery and optimising production processes; both are achieved through the implementation of MAXImolding technologies.
2) Eliminating the use of environmentally harmful shielding gases: MAXImolding process uses near solidus temperature slurry and a small amount of appropriate inert gases such as argon.
3) Use alternative energy sources: switching from fossil fuels to renewable energy sources (e.g. solar, wind or hydro) can significantly reduce the carbon footprint; using electrical heat with high efficiency.
4) Reuse of process heat: MAXImolding reuses process heat to preheat material chips. The MAXImolding process is completely sealed and no outside air enters the process.
Our Solution
The MAXImolding system deploys a patented high-thermal mass reactor with multiple electric heater zones, and with precise and accurate temperature control. We prefer solar, wind or hydroelectric power to provide continuous high-temperature process heat up to 585°C to bring the light metal to a semi-solid slurry state. For example, Mg alloys at 540°C.
Modular solution, easy to scale with minimal retrofitting downtime and low Capex spending.
MAXImolding® technology perfectly fulfills customers requirements – CO2 free continuous and easily integrated process heat at very competitive cost. This is especially the case when magnesium is extracted from seawater and when renewable electricity is used.
Process heat (conduction heat transfer) up to 600°C.
Our Offer
Firstly, we offer a customised reactor for the production of semi-solid thixotropic magnesium slurries from 0.75kg to 75kg.
This is used for the retrofitting of a standard, but modified, cold chamber die casting machine.
Secondly, we offer a complete turnkey casting cell. This is a standard but modified cold chamber die casting machine retrofitted with our reactor with two chip conditioners, including a mould with electric surface heating and internal water mist cooling, robotic system for part removal and mould spraying, conveyor unit with four cooling fans, chip storage, pipework and vacuum chip handling system.
MAXImolding is a new one-step, fully enclosed, high-performance metal injection moulding process (from solid ingot to metal chip to semi-solid slurry to solid part) developed and patented by German start-up MAXImolding! Technology GmbH.
At the heart of the process is a highly efficient, custom-designed reactor for the production of semi-solid magnesium slurry. The reactor significantly reduces energy and material consumption, but does not pollute the environment. Zero CO2 emissions when powered by renewable energy.
This cutting-edge, patented innovation frees operators from complex production processes and allows them to participate in simple, cost-effective and satisfying tasks. The result is the efficient production of high performance magnesium castings on a large scale for the global market.
Our Promise
As a user of our technologies, you will be able to:
1. reduce energy losses by up to 90%.
2. reduce material consumption by up to 50%.
3. reduce emissions by up to 70% and, if powered by renewable energy, eliminate them altogether.
Our Applications
Applications of MAXImolding
This means the production of lightweight, high performance, semi-solid magnesium parts ($3 billion a year global market estimate).
Mobility Market, transporting people or goods by land, sea or air
International Magnesium Association (intlmag.org)
Consumer Electronics Market
General Purpose Market
About us
Edo Meyer
Strategy & Operations
Work and organisational psychology
Ph.D. Candidate, U of Vienna
Ashley Stone
Technology & Products
Inventor, non-linear thinker
Serial entrepreneur, P. Eng.
We strive for peace and prosperity. We have high moral and ethical standard and professional and personal integrity. Our technology cannot be used for military applications.
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Contact us
Looking for more information about Maximolding and our technology? We’d love to get in touch!
MAXImolding!
Teisendorfer Str. 68
83317 Teisendorf, Bavaria, Germany
+49 157 7948 1915