We have solutions to all these problems. You can create better semisolid Megacastings by arranging our injectors in an array on the top plate of a pull-down press at a fraction of the cost of a Giga Castings machine. We think differently: Less is more. Other thinking: "More is better," but they do not understand the simple rule that productivity is the ratio of output to input. More input requires more money. Ashley Stone at as@maxi-molding.com
Semi-Solid Casting definitely is a solution to the technical issues Gigacastings are facing. However, what we are talking about is that there is a financial crisis coming. Low sales volume on more car brands let’s the air get thinner and thinner.
So, investing more will be near impossible for most operators. If I understood it correctly, for your solution you need to change the whole shot end and buy special billets? Is your solution already in production or is it still a PowerPoint design?
We are an ex-Canada machine system builder now based in Germany. We have over 15 patents and more than 40 years of experience. Our scientific knowledge of X-ray and thixomolding machine building is based on more than 400 patents. We are currently accepting pre-orders for a semisolid feeder reactor (see www.maxi-molding.com or www.jacobsenxray.com) and for a CCDC machine, as well as a vertical semisolid light metal injection molding machine. We will start with magnesium alloys, followed by aluminum alloys. Our MEGApress(TM) can be built in partnership with a press manufacturer, such as abk Pressenbau. This was originally a PowerPoint design in summer 2006. This transformative technology will bring significant benefits to the end user. We appreciate your Request for Quote at as@maxi-molding.com
Thank you for your follow-up. While no full-scale systems are in operation yet, we have several pre-orders and active discussions with key partners, and pilot units are planned for early deployment. Our technology builds on decades of proven work in semisolid processing, X-ray system development, and machine tool engineering—this is not a conceptual leap, but a highly refined evolution.
Our semisolid slurry reactor is designed for retrofitting existing cold-chamber die casting systems, minimizing capital investment and downtime—precisely because we understand the financial pressures the industry faces. This modularity and cost-efficiency differentiate us from GigaCasting-type mega-investments. We are focused on enabling lean, scalable productivity: less input, more output.
We invite light metal foundry operators to engage directly—test data, case study previews, and pre-order specifications are available. Let’s turn this conversation into collaboration.
Enjoy the time when everything is on PowerPoint and CAD. Reality hits hard very quickly. For the Rheometal Process, we needed to develop new plunger tips and release agents. It works now flawlessly with the existing infrastructure in a foundry.
Let's talk again when you've moved out of the design phase and have the first series in production.
Thank you for the opportunity to elaborate further. Our semisolid SIMA (Strain Induced Melt Activation) process fundamentally differs from traditional casting methods by avoiding the need for fully fluidized molten metal. Instead, it begins with metal chips or granules at room temperature, which are first cleaned and Argon pre-heated in our pre-conditioning reactor. These are then precisely dosed into the main reactor and heated from top to bottom to reach the semisolid temperature. This controlled heating significantly reduces energy consumption compared to conventional melting and holding processes. Unlike the Rheocasting process, our SIMA process never reaches a fully fluidized state.
Our casting cell consists of a vertically oriented semisolid metal injection molding machine—designed, invented, and installed by us—two pre-conditioning reactors (hoppers), a mold with jet cooling (a mix of 20% water and 80% air), and precisely temperature-controlled electrical wire heaters. The system also includes a robotic part removal unit, micro-spraying, and real-time X-ray and visual inspection systems to detect internal and surface defects. An AI-powered cloud system runs and continuously improves the process cycle by cycle.
We believe this solution will be highly beneficial to light alloy foundries, enabling them to produce high-quality parts with lower energy and material usage, and zero pollution when powered by renewable electricity such as solar, wind, or hydro. It is time for a complete transformation of light alloy foundries toward sustainable, efficient production.
Would you like to test our solution on a small scale? You can do so by ordering semisolid slurry feeder. This will be added to your existing Cold Chamber Die Casting (CCDC) machine.
Thank you for sharing your insights on the RheoMetal™ EEM process. While I do not have in-depth knowledge of the RheoMetal™ EEM process used by Comptech, I applaud your efforts in successfully introducing semisolid processing to aluminum alloy foundries. It’s encouraging to see different approaches advancing the industry.
You have chosen the rheo-route, and we have chosen the SIMA thixo-route approach for generating semisolid slurry. I understand your concerns about temperature-controlled semisolid processes potentially posing challenges for RheoMetal™ EEM. However, I believe those concerns may not directly apply to our SSM-SIMA process.
I encourage you to review the scientific papers and patents by Dr. Frank Czerwinski, as well as his book “Magnesium Injection Molding”, which provide extensive research on the SIMA process. SIMA has been known and studied for some time, and our implementation is both patented and innovative.
Our approach adapts a horizontal thixomolding machine into a vertical configuration. We removed the screw and backflow valve, replacing them with an injection piston and two positive valves. The heaters are positioned around a thermal mass cylinder, enabling very precise temperature control. Metal chips are heated from top to bottom, generating a semisolid slurry, on-demand, that is injected vertically into the mold via direct injection—eliminating the need for sprues and runners. The entire machine is mounted on a pull-down press, allowing us to control the entire process chain from solid chips to semisolid slurry, injection, and finally to producing high-quality solid parts. We believe this design addresses many of the challenges associated with temperature fluctuations and process stability. We welcome further technical discussions and collaboration to explore the strengths and limitations of both approaches.
Thank you for the opportunity to elaborate further. Our semisolid SIMA (Strain Induced Melt Activation) process fundamentally differs from traditional casting methods by avoiding the need for fully fluidized molten metal. Instead, it begins with metal chips or granules at room temperature, which are first cleaned and Argon pre-heated in our pre-conditioning reactor. These are then precisely dosed into the main reactor and heated from top to bottom to reach the semisolid temperature. This controlled heating significantly reduces energy consumption compared to conventional melting and holding processes. Unlike the Rheocasting process, our SIMA process never reaches a fully fluidized state.
Our casting cell consists of a vertically oriented semisolid metal injection molding machine—designed, invented, and installed by us—two pre-conditioning reactors (hoppers), a mold with jet cooling (a mix of 20% water and 80% air), and precisely temperature-controlled electrical wire heaters. The system also includes a robotic part removal unit, micro-spraying, and real-time X-ray and visual inspection systems to detect internal and surface defects. An AI-powered cloud system runs and continuously improves the process cycle by cycle.
We believe this solution will be highly beneficial to light alloy foundries, enabling them to produce high-quality parts with lower energy and material usage, and zero pollution when powered by renewable electricity such as solar, wind, or hydro. It is time for a complete transformation of light alloy foundries toward sustainable, efficient production.
Would you like to test our solution on a small scale? You can do so by ordering semisolid slurry feeder. This will be added to your existing Cold Chamber Die Casting (CCDC) machine.
I work daily with Rheocasting and a temperature-controlled Semi-Solid process is recipe for disaster! The fluctuations in the liquidus temperature of process variations in the alloy composition are higher than temperature-difference between different solid fractions. The temperature difference between 20 and 40% solid fraction is just 0.8 Kelvin. That is the difference between laminar and turbulent fill. See the article for more insights:
Thank you for sharing your insights on the RheoMetal™ EEM process. While I do not have in-depth knowledge of the RheoMetal™ EEM process used by Comptech, I applaud your efforts in successfully introducing semisolid processing to aluminum alloy foundries. It’s encouraging to see different approaches advancing the industry.
You have chosen the rheo-route, and we have chosen the SIMA thixo-route approach for generating semisolid slurry. I understand your concerns about temperature-controlled semisolid processes potentially posing challenges for RheoMetal™ EEM. However, I believe those concerns may not directly apply to our SSM-SIMA process.
I encourage you to review the scientific papers and patents by Dr. Frank Czerwinski, as well as his book “Magnesium Injection Molding”, which provide extensive research on the SIMA process. SIMA has been known and studied for some time, and our implementation is both patented and innovative.
Our approach adapts a horizontal thixomolding machine into a vertical configuration. We removed the screw and backflow valve, replacing them with an injection piston and two positive valves. The heaters are positioned around a thermal mass cylinder, enabling very precise temperature control. Metal chips are heated from top to bottom, generating a semisolid slurry, on-demand, that is injected vertically into the mold via direct injection—eliminating the need for sprues and runners. The entire machine is mounted on a pull-down press, allowing us to control the entire process chain from solid chips to semisolid slurry, injection, and finally to producing high-quality solid parts. We believe this design addresses many of the challenges associated with temperature fluctuations and process stability. We welcome further technical discussions and collaboration to explore the strengths and limitations of both approaches.
We have solutions to all these problems. You can create better semisolid Megacastings by arranging our injectors in an array on the top plate of a pull-down press at a fraction of the cost of a Giga Castings machine. We think differently: Less is more. Other thinking: "More is better," but they do not understand the simple rule that productivity is the ratio of output to input. More input requires more money. Ashley Stone at as@maxi-molding.com
Semi-Solid Casting definitely is a solution to the technical issues Gigacastings are facing. However, what we are talking about is that there is a financial crisis coming. Low sales volume on more car brands let’s the air get thinner and thinner.
So, investing more will be near impossible for most operators. If I understood it correctly, for your solution you need to change the whole shot end and buy special billets? Is your solution already in production or is it still a PowerPoint design?
We are an ex-Canada machine system builder now based in Germany. We have over 15 patents and more than 40 years of experience. Our scientific knowledge of X-ray and thixomolding machine building is based on more than 400 patents. We are currently accepting pre-orders for a semisolid feeder reactor (see www.maxi-molding.com or www.jacobsenxray.com) and for a CCDC machine, as well as a vertical semisolid light metal injection molding machine. We will start with magnesium alloys, followed by aluminum alloys. Our MEGApress(TM) can be built in partnership with a press manufacturer, such as abk Pressenbau. This was originally a PowerPoint design in summer 2006. This transformative technology will bring significant benefits to the end user. We appreciate your Request for Quote at as@maxi-molding.com
So, to summarize no system has been built or ordered so far?
Thank you for your follow-up. While no full-scale systems are in operation yet, we have several pre-orders and active discussions with key partners, and pilot units are planned for early deployment. Our technology builds on decades of proven work in semisolid processing, X-ray system development, and machine tool engineering—this is not a conceptual leap, but a highly refined evolution.
Our semisolid slurry reactor is designed for retrofitting existing cold-chamber die casting systems, minimizing capital investment and downtime—precisely because we understand the financial pressures the industry faces. This modularity and cost-efficiency differentiate us from GigaCasting-type mega-investments. We are focused on enabling lean, scalable productivity: less input, more output.
We invite light metal foundry operators to engage directly—test data, case study previews, and pre-order specifications are available. Let’s turn this conversation into collaboration.
Enjoy the time when everything is on PowerPoint and CAD. Reality hits hard very quickly. For the Rheometal Process, we needed to develop new plunger tips and release agents. It works now flawlessly with the existing infrastructure in a foundry.
Let's talk again when you've moved out of the design phase and have the first series in production.
Thank you for the opportunity to elaborate further. Our semisolid SIMA (Strain Induced Melt Activation) process fundamentally differs from traditional casting methods by avoiding the need for fully fluidized molten metal. Instead, it begins with metal chips or granules at room temperature, which are first cleaned and Argon pre-heated in our pre-conditioning reactor. These are then precisely dosed into the main reactor and heated from top to bottom to reach the semisolid temperature. This controlled heating significantly reduces energy consumption compared to conventional melting and holding processes. Unlike the Rheocasting process, our SIMA process never reaches a fully fluidized state.
Our casting cell consists of a vertically oriented semisolid metal injection molding machine—designed, invented, and installed by us—two pre-conditioning reactors (hoppers), a mold with jet cooling (a mix of 20% water and 80% air), and precisely temperature-controlled electrical wire heaters. The system also includes a robotic part removal unit, micro-spraying, and real-time X-ray and visual inspection systems to detect internal and surface defects. An AI-powered cloud system runs and continuously improves the process cycle by cycle.
We believe this solution will be highly beneficial to light alloy foundries, enabling them to produce high-quality parts with lower energy and material usage, and zero pollution when powered by renewable electricity such as solar, wind, or hydro. It is time for a complete transformation of light alloy foundries toward sustainable, efficient production.
Would you like to test our solution on a small scale? You can do so by ordering semisolid slurry feeder. This will be added to your existing Cold Chamber Die Casting (CCDC) machine.
Thank you for sharing your insights on the RheoMetal™ EEM process. While I do not have in-depth knowledge of the RheoMetal™ EEM process used by Comptech, I applaud your efforts in successfully introducing semisolid processing to aluminum alloy foundries. It’s encouraging to see different approaches advancing the industry.
You have chosen the rheo-route, and we have chosen the SIMA thixo-route approach for generating semisolid slurry. I understand your concerns about temperature-controlled semisolid processes potentially posing challenges for RheoMetal™ EEM. However, I believe those concerns may not directly apply to our SSM-SIMA process.
I encourage you to review the scientific papers and patents by Dr. Frank Czerwinski, as well as his book “Magnesium Injection Molding”, which provide extensive research on the SIMA process. SIMA has been known and studied for some time, and our implementation is both patented and innovative.
Our approach adapts a horizontal thixomolding machine into a vertical configuration. We removed the screw and backflow valve, replacing them with an injection piston and two positive valves. The heaters are positioned around a thermal mass cylinder, enabling very precise temperature control. Metal chips are heated from top to bottom, generating a semisolid slurry, on-demand, that is injected vertically into the mold via direct injection—eliminating the need for sprues and runners. The entire machine is mounted on a pull-down press, allowing us to control the entire process chain from solid chips to semisolid slurry, injection, and finally to producing high-quality solid parts. We believe this design addresses many of the challenges associated with temperature fluctuations and process stability. We welcome further technical discussions and collaboration to explore the strengths and limitations of both approaches.
Thank you for the opportunity to elaborate further. Our semisolid SIMA (Strain Induced Melt Activation) process fundamentally differs from traditional casting methods by avoiding the need for fully fluidized molten metal. Instead, it begins with metal chips or granules at room temperature, which are first cleaned and Argon pre-heated in our pre-conditioning reactor. These are then precisely dosed into the main reactor and heated from top to bottom to reach the semisolid temperature. This controlled heating significantly reduces energy consumption compared to conventional melting and holding processes. Unlike the Rheocasting process, our SIMA process never reaches a fully fluidized state.
Our casting cell consists of a vertically oriented semisolid metal injection molding machine—designed, invented, and installed by us—two pre-conditioning reactors (hoppers), a mold with jet cooling (a mix of 20% water and 80% air), and precisely temperature-controlled electrical wire heaters. The system also includes a robotic part removal unit, micro-spraying, and real-time X-ray and visual inspection systems to detect internal and surface defects. An AI-powered cloud system runs and continuously improves the process cycle by cycle.
We believe this solution will be highly beneficial to light alloy foundries, enabling them to produce high-quality parts with lower energy and material usage, and zero pollution when powered by renewable electricity such as solar, wind, or hydro. It is time for a complete transformation of light alloy foundries toward sustainable, efficient production.
Would you like to test our solution on a small scale? You can do so by ordering semisolid slurry feeder. This will be added to your existing Cold Chamber Die Casting (CCDC) machine.
I work daily with Rheocasting and a temperature-controlled Semi-Solid process is recipe for disaster! The fluctuations in the liquidus temperature of process variations in the alloy composition are higher than temperature-difference between different solid fractions. The temperature difference between 20 and 40% solid fraction is just 0.8 Kelvin. That is the difference between laminar and turbulent fill. See the article for more insights:
https://casting-campus.com/solid-fraction-matters-in-rheocasting/
Thank you for sharing your insights on the RheoMetal™ EEM process. While I do not have in-depth knowledge of the RheoMetal™ EEM process used by Comptech, I applaud your efforts in successfully introducing semisolid processing to aluminum alloy foundries. It’s encouraging to see different approaches advancing the industry.
You have chosen the rheo-route, and we have chosen the SIMA thixo-route approach for generating semisolid slurry. I understand your concerns about temperature-controlled semisolid processes potentially posing challenges for RheoMetal™ EEM. However, I believe those concerns may not directly apply to our SSM-SIMA process.
I encourage you to review the scientific papers and patents by Dr. Frank Czerwinski, as well as his book “Magnesium Injection Molding”, which provide extensive research on the SIMA process. SIMA has been known and studied for some time, and our implementation is both patented and innovative.
Our approach adapts a horizontal thixomolding machine into a vertical configuration. We removed the screw and backflow valve, replacing them with an injection piston and two positive valves. The heaters are positioned around a thermal mass cylinder, enabling very precise temperature control. Metal chips are heated from top to bottom, generating a semisolid slurry, on-demand, that is injected vertically into the mold via direct injection—eliminating the need for sprues and runners. The entire machine is mounted on a pull-down press, allowing us to control the entire process chain from solid chips to semisolid slurry, injection, and finally to producing high-quality solid parts. We believe this design addresses many of the challenges associated with temperature fluctuations and process stability. We welcome further technical discussions and collaboration to explore the strengths and limitations of both approaches.