Magnesium Die Casting Manufacturer

Name: Magnesium Die Casting Manufacturer
Brand: The Federal Group USA
Price: Quote Required USD
Availability: InStock

The Federal Group USA is a QMS 9001:2015 Certified magnesium die casting manufacturer specializing in custom lightweight components. We support medium- to high-volume manufacturing programs with a complete solution that includes casting, secondary CNC machining, surface finishing, and final assembly.

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Why Choose TFG for Magnesium Die Casting

We cast common grades like AZ91D and AM60B to meet the exact mechanical properties and strength-to-weight ratio your application requires.

Our engineering team controls melting parameters and injection speeds to maintain consistent part quality across large production runs.

Our QMS 9001:2015 Certified facilities use dimensional inspections and documented procedures to verify every part meets specification.

We maintain strict control over dimensional tolerances and thin-wall sections to support precise fit and function.

Die Casting Case Study

A leading manufacturer approached The Federal Group to provide aluminum die casting services for a part that could be used “as cast”—without further machining—while ensuring leak-free assembly.

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Magnesium Die Casting Equipment & Technology

Our magnesium die casting operations use advanced high-pressure die casting equipment and automated production technology to produce complex, lightweight components with consistent quality at medium to high volumes.

Cold Chamber Die Casting Machines

We use these machines to inject molten metal into the steel mold at high pressures, making them well-suited for producing dense structural components.

Hot Chamber Die Casting Machines

We use this equipment to keep the injection mechanism submerged in molten magnesium, achieving fast cycle times for high-volume production runs.

Multi-Slide Die Casting Machines

We use multi-slide systems to form complex near-net-shape geometries in a single step, reducing the need for secondary operations.

Magnesium Alloys for Die Casting

We manufacture magnesium die castings using a range of alloys selected for their combination of strength, weight, castability, corrosion resistance, and impact performance. Common alloy options include:

AZ91D: A widely used magnesium die casting alloy offering a strong combination of strength, corrosion resistance, castability, and dimensional stability. Suitable for a broad range of structural and industrial components.
AM60B: Offers excellent ductility and impact resistance, making it well suited for components where toughness and energy absorption are important.
AM50: Provides good ductility and impact performance with excellent castability, making it suitable for applications requiring thin walls and complex geometries.
Customer-specified alloys: We can manufacture to customer-specified magnesium alloy requirements based on the application, performance requirements, and applicable specifications.

Magnesium is one of several materials available through our die casting capabilities, which include a range of alloys and casting options for medium- to high-volume production.

Secondary Processes and Finishing Capabilities

Post-production machining: Our advanced CNC centers achieve tight dimensional tolerances on critical mating surfaces.
Bead blasting: This process creates a uniform surface finish and removes minor casting imperfections.
Anodizing: Anodic coatings improve the natural corrosion resistance of raw magnesium components.
Powder coating: This durable finish protects parts from harsh environments while providing a precise cosmetic appearance.
Assembly: We combine your cast components with custom hardware to deliver ready-to-use subassemblies.

Request a Quote for Custom Magnesium Die Castings

Looking for a reliable manufacturing partner for custom magnesium die castings? TFG USA manufactures complex, lightweight magnesium die cast parts for medium- to high-volume production programs.

Submit your drawings, 3D models, material requirements, annual volumes, finishing requirements, and quality specifications. Our team will review your requirements and determine the appropriate manufacturing process and production approach for your application.

Contact us today to discuss your magnesium die casting project and request a quote.

      EXCELLENT  
   Based on 14 reviews 
    
 
 
 
   
 
 
       Posted on Google  
   
   Rob Buchanan 
 
 
 
 Trustindex verifies that the original source of the review is Google. Quality parts at a fair price. They are a great company to work with.
  
 
      Posted on Google  
   
   David Detuccio 
 
 
 
 Trustindex verifies that the original source of the review is Google. The Federal Group has demonstrated professionalism, responsiveness, and a willingness to collaborate during the initial stages of our relationship. Communication has been timely, and they have shown a commitment to understanding our requirements and business expectations. Responsive communication and follow-up. Competitive pricing and commercial flexibility. Good product/service quality during initial orders. Cooperative approach to resolving issues and answering questions. Demonstrated interest in building a long-term partnership. Alanna and Sandor are amazing!
  
 
      Posted on Google  
   
   Judd Stretcher 
 
 
 
 Trustindex verifies that the original source of the review is Google. Great communication and quality parts at a fair price. They really make sure your happy with your parts.
  
 
      Posted on Google  
   
   Jonathon Lanham 
 
 
 
 Trustindex verifies that the original source of the review is Google. Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!
  
 
      Posted on Google  
   
   Sean Brockhouse 
 
 
 
 Trustindex verifies that the original source of the review is Google. Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines.  Outstanding customer service!!
  
 
      Posted on Google  
   
   Melissa Quiroz 
 
 
 
 Trustindex verifies that the original source of the review is Google. Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!
  
 
      Posted on Google  
   
   Alex Armstrong 
 
 
 
 Trustindex verifies that the original source of the review is Google. Steve was great to work with and was always available when needed.
  
 
      Posted on Google  
   
   Jon Ramsey 
 
 
 
 Trustindex verifies that the original source of the review is Google. Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success. Would recommend and I plan to use them for future projects. Thanks again Mike and TFG team.
  
 
      Posted on Google  
   
   Nic Robinson 
 
 
 
 Trustindex verifies that the original source of the review is Google. Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.