Magnesium Machining Services

High-end CNC systems give precise results for milling, turning, and machining with multiple axes.
The operator is skilled in machining AZ, ZK, and AM series alloys by using proper temperature and chip removal controls.
Everything from materials to designing in CAD to finishing the parts is done within the same company.
Quality is central to the process, including regular inspection, checks of parts after production, and records are kept according to ISO 9001 rules.

We are best in providing machining of magnesium and offer parts that provide the metal’s outstanding balance between strength and weight. Thus, they have numerous applications in different fields like aerospace, defense, automotive, robotics, and electronics. With our precise machines and expert personnel, we provide magnesium parts that offer high quality, precise measurements, and dependable performance. For both small and big orders, we can provide machining that is precise, quick, and of high quality.

What is Magnesium Machining?

CNC machines are used for machining to mold magnesium alloy parts into their required shape. Magnesium is highly recognized as the lightest material used in engineering, but it is also tough and sturdy. Still, it becomes quite reactive if machined, so it is necessary to use certain tools, coolant, and install dust controls. Some challenges in machining are stopping burns, keeping chips contained, and maintaining a good surface.

How Does Magnesium Machining Work?

Machining this metal requires both careful work and attention to safety. The process begins by thoroughly reviewing CAD to enhance the way parts are laid out, cutting will take place, and the fixtures are created. We make sure feed rates are specified and the tools are diamond-coated or PVD-coated to prevent chips from accumulating. Misting the site with coolant or oil keeps the area cool, prevents things from becoming too hot, and helps eliminate sparks. These machines quickly carry out chip removal to prevent turnings from sparking combustion. After they are machined, all parts are deburred, cleaned to get rid of residue, and closely checked for surface quality.

Common Operations We Do

You’ll find these magnesium machining services from us:

CNC Milling – Creates complex shapes and designs by using 3 to 5 different axes.

CNC Turning – Spinning cylindrical objects, referred to as housings and spacers, at a fast speed.

Drilling & Tapping –It ensures the hole is the right size with correct chip movement and threaded structure.

Gear Cutting & Broaching –These are operations targeted at making internal and external gear features.

Finishing the Surface – Methods such as bead blasting and anodizing are used to modify the finish and boost how the part looks.

Properties of Magnesium Material

Magnesium is a metal used in construction due to its special balance of physical, thermal, and chemical traits. Here are some of the main properties of metal that let it be machined accurately:

Lightweight

Magnesium is the lightest metal you can use for structures because it weighs much less than aluminum or steel. On this basis, it is much sought after in aerospace, automotive, and electronics, as making things lighter can make them perform and function better.

High Machinability

A clear advantage of magnesium is that it is very easy to machine. The cut takes less power, there is less heat created during cutting, and the tools last longer. This way, the time needed to make parts is reduced, costs are lower, and the level of accuracy is maintained.

Great Strength-to-Weight Ratio

Although magnesium isn’t as strong as steel, it is very strong about how light it is. Because it needs only a small thickness to be strong, this material is wonderful for parts that need some structure but would become too heavy with heavier metal.

Thermal Conductivity

Magnesium alloys efficiently release heat from engine casings, heat sinks, and electronic housing, which is very important. This way, the computer’s operability is maintained and critical parts are protected from overheating.

Vibration Damping

The presence of magnesium helps absorb vibrations and shock, so it is perfect for uses requiring movement. It adds comfort to vehicle seats and also lowers noise and wear in different mechanical parts.

Recyclability

It is possible to recycle magnesium again and again without losing its unique qualities. Apart from using fewer resources, this also supports companies that care about the environment.

Suitable Materials for Magnesium Machining

Here are some of the suitable materials for magnesium machining:

Type	Key Properties	Common Uses
AZ31	Great machinability, corrosion-resistant, lightweight	Aerospace panels, electronics, housings
AZ61	Higher strength, good surface finish	Auto parts, tools, and sporting equipment
AM60	High ductility, impact resistance	Crash zones, dashboards, safety parts
AM50	Lightweight, good formability	Transmission cases, suspension components
ZK60	High strength, creep resistance	Bike frames, aerospace gears, robotics
ZK61	Tougher than ZK60, dimensionally stable	Drones, defense equipment, motorsport frames
AE42	Creep and corrosion resistant	Engine blocks, gearbox housings
AZ91D	Most used alloy, excellent strength-to-weight	Electronics, power tools, and auto parts
Elektron 21	High-temp and creep resistance, aerospace-grade	Jet engines, satellites, and military structures

Considerations to Cut Costs when Machining Magnesium

Here are some tips you must follow to cut the magnesium machining cost:

Organize the parts so that the machinery follows easier paths and tool switches are reduced.
Fix similar parts in the same setup, as it requires less time to configure tools and fixes.
Choose useful coatings like PVD on your tools to lessen both the wear and the stopping time.
Pick the right alloy over a higher grade material when you can.
Plan your work so you have to do as little deburring and surface preparation as possible.

Applications of Magnesium Machining

When applications require strength, being lightweight, and exceptional thermal performance, magnesium proves to be excellent.

Aerospace:Brackets, frames, and parts of satellites
Automotive: You can choose dashboards, steering wheel hubs, and various performance pieces.
Electronics: Laptop enclosures, heat dissipating parts for computers, and camera shells
Equipment for Sports: Bike pieces, helmets, and tools for safety
Robotics & Machinery: Some of our products here include gearboxes and housings, as well as instrument panels.

Advantages of Magnesium Machining

Here are the following advantages of magnesium machining;

It Matters to be Lightweight Designing for less weight, using 35% less weight than aluminum.
Thermal management must happen – excellent thermal conductivity.y
The importance of lightweight materials with high strength helps make them ideal for tough jobs.
The process must be easy to manufacture and lead to fast production.
A lighter system leads to savings in the supply chain.n

Challenges in Machining Magnesium

There are advantages to using magnesium, but it still needs to be carefully looked after.

Hazard of ignition – Fine chips are flammable; standard coolant and chip placement procedures decrease the risk.
Accumulation of Chips –There must be regular cleaning to lower the risk of fires and damaged surfaces.
Hardened Alloys Are Brittle – During tooling, place parts carefully to avoid catching cracks and stress points.
Corrosion Risk –It is important to apply a protective coating or anodize this material.
Small Clamping Damage – Can only occur with a well-planned fixture design.

Finishing Processes for Machining Magnesium

We offer various suggestions to protect magnesium and raise its effectiveness.

Anodizing – with chromate sealing – for both protection against corrosion and attractive results.
Metal plating and conversion – Choose zinc, nickel, or chromate to make the coating more durable.
Powder Coating – A smooth and long-lasting surface comes in your selected colors.
Bead Blasting –Leaves a smooth matte look behind and hides minor surface marks.
Passivation – Eliminates any free magnesium to secure the surface and shield it from oxidation.

Get Magnesium Parts from TOPS Precision

At TOPS Precision, we guide you from the right material to design improvement, machining, finishing touch-ups, and inspection. We start collaborating as soon as you send your CAD files and keep going till each part is ready to your specifications.

Choose us for the Best Magnesium Machining Services

Quality and reliability are the main principles behind our processes. All sections are checked for dimensions, looked at visually, and additional optional hardness or metallurgical tests are available. We have an ISO-approved quality management system and give first article inspection reports and certificates for the materials we supply. If the result falls short of your needs, we’ll keep going until everything is accurate and prepared as you want it.

FAQs About Magnesium CNC Machining

1. Can machines handle magnesium in water-cooled situations safely?

Yes, but this happens only if there is a proper coolant system in place and for the chips’ removal. To keep fires from occurring, we use oil-mist systems with high pressure and enclosures.

2. Is it possible to machine magnesium very thin?

Most metal alloys work up to 0.020″ (0.5 mm) wall thickness regularly, unless there are other considerations. It is possible to create even narrower features by carefully writing the code.

3. Is post-machining heat treatment available?

Yes, whenever you choose, we can perform post-machining and aging treatments for different alloys.

4. Is it possible to anodize magnesium parts?

It’s possible to chemically work with magnesium to improve its brightness and cover it with a sealant. But, anodizing that type of alloy is not an option.

5. When should a typical order be expected?

Prototype orders take 7–10 days for completion. Orders of 100 parts or more are ready to ship within 2 to 3 weeks, mostly depending on what materials and finishes you choose.

6. Is it possible for you to machine aerospace-grade alloys?

Yes, AZ31 and ZK60 alloys are best for the aerospace industry, and all the necessary documentation is available for each part.