# Thixocast, Inc.

This MFR.ID profile was supplied, reviewed, and approved by Thixocast, Inc.. Originally approved on 7/3/2025; last updated 5/14/2026. Capability data is manufacturer-approved for public sourcing and RFQ use.

## Profile Links

- Canonical profile: https://mfr.io/thixocast
- JSON data: https://mfr.io/thixocast.json

## Company Overview

Thixocast’s semi-solid aluminum thixocasting line combines in-house billet casting, four 400-ton cells, T6 solution-aging furnaces, and 3/4-axis CNC machining to deliver pore-free, near-net parts that outperform high-pressure die casting (HPDC). From its 31 000-ft² Lakewood, CO plant—certified to AS9100D and ISO 9001:2015—Thixocast supplies aerospace, defense, automotive & transport, medical, marine, and industrial OEMs. Integrated DFM support, on-site tooling, and managed anodize, powder-coat, and plating services provide turnkey, ready-to-install components with repeat-order lead times of just four weeks.

## Quick Reference

- Processes: Semi-Solid Aluminum Thixocasting (SSM), Heat-Treating & Thermal Processing, Tool & Die (Fixtures & Gages), CNC Machining, Surface Treatment & Finishing
- Lead Time: 3-16 weeks
- Production Scale: Prototype (1-10 parts), Short Run (11-500 parts), Medium Run (501-10000 parts), Mass Production (10001+ parts)
- Location: Lakewood, CO 80214
- Employees: 60-70
- Revenue: $10M-$25M
- Founded: 1999
- Contact: jon.young@thixocast.com - +1 303-781-0234
- Verified: Manufacturer Approved

## Capabilities

### Semi-Solid Aluminum Thixocasting

Using proprietary electromagnetic continuous casting and induction-heated billets (2–5" diameter), Thixocast injects aluminum in a semi-solid state under ~170 MPa to form dense, porosity-free castings with forging-like properties. Near-net shapes achieve as-cast ±0.005" tolerances, minimizing secondary machining. The process supports heat-treatable alloys rarely feasible in conventional die casting, and fully integrates with Thixocast’s in-house heat treatment, CNC machining, and finishing services. AS9100D/ISO 9001 controls, real-time SPC, and multi-cavity tooling deliver cost-effective, high-integrity parts for automotive, aerospace, and medical applications.

- Process: Semi-Solid Aluminum Thixocasting (SSM)
- Highlights: Forge-like mechanical properties with <0.5% internal porosity and near-wrought strength, Wall sections down to 0.8 mm and as-cast ±0.005" dimensional accuracy, Part weights from 5 g up to 3 kg; multi-cavity tools boost high-volume throughput, Electromagnetically cast billet feedstock (2–5" dia.) ensures non-dendritic, globular microstructure, Supports heat-treatable alloys (e.g., 6061, 7075) not feasible in standard die casting, AS9100D / ISO 9001 certified quality system with PPAP & FAI capability, Fully integrated with in-house heat treatment, CNC, and finishing for turnkey supply
- Subprocesses: Induction Slug Heating, High-Pressure Squeeze Casting, Die Thermal Management, Real-Time SPC
- Specifications:
  - Part Weight Range: Min: 0.18 oz, Max: 6.6 lb (5-3000 g) - Covers sub-ounce precision up to 3 kg structural castings.
  - Porosity: 0-0.5 % - <0.5% micro-porosity verified by X-ray inspection; enables leak-tight parts.
  - Heat Treatment Options: F, T5, T6, T7 - Fully compatible with in-house solution treat/age for maximum strength.
  - Certifications & Standards Compliance: AS9100D, ISO 9001:2015, NADCA Precision Die-Casting tolerances - External audits confirm PPAP/FAI readiness for aerospace/automotive.
  - Typical Mechanical Properties (6061 T6): Ultimate Tensile Strength ≈ 310 MPa, Yield Strength ≈ 270 MPa, Elongation ≈ 10 % - SSM test bars approach wrought properties; final results depend on geometry.
  - Dimensional Tolerance (As Cast): 0.005 in (0.13 mm) - ±0.005" on critical features; secondary machining can tighten further.
  - Minimum Wall Thickness: 0.03 in (0.8 mm) - Achievable for semi-solid aluminum with carefully engineered gating.
  - Common Aluminum Alloys: A356, A357, 319, 6061, 6082, 7075 - Both cast and wrought alloys can be processed; custom chemistries on request.
  - Typical Surface Finish (As Cast): 32-125 RMS (0.8-3.2 µm Ra) - Depends on gate design and die condition; ~1.6 µm Ra typical.
  - Primary Equipment: 4 × 400-ton semi-solid casting presses, In-house horizontal continuous caster, 8-station induction billet-heater carousels - Scalable capacity for diverse part sizes and production volumes.

### In-House Heat Treatment

Thixocast solution-treats, quenches, and ages aluminum castings on site using AMS 2750 Class 2 furnaces, an agitated water/glycol quench tank, and calibrated aging ovens. Because semi-solid castings are nearly free of entrapped gas, they remain blister-free during solution treatment and achieve uniform mechanical properties. With <10 s quench transfer preserving magnesium in solution, final hardness and tensile strength can increase by 30–50%. All heat-treat lots ship with AS9100D traceability, furnace charts, and load certifications—eliminating subcontract delays and property scatter. Periodic hardness checks and ASTM E8 tensile tests confirm target temper is achieved for critical applications.

- Process: Heat-Treating & Thermal Processing
- Highlights: AMS 2750 Class 2 ±3 °C uniformity with real-time data logging, Tempers F, T5, T6, T7 for A356, 6061, 6082, 7075 & custom alloys, 1 000 × 1 000 × 1 200 mm, 680 kg load envelope per charge, <10 s quench transfer controls distortion; scatter <3 %, 30–50 % hardness & tensile gain, shipped with full FAI traceability, Blister-free solution treat thanks to porosity-free semi-solid castings, Hardness and tensile properties validated by lot-based coupon testing
- Subprocesses: Solution Heat Treatment, Rapid Agitated Quench Transfer, Artificial Aging, Hardness & Tensile Coupon Testing, Lot Traceability & Certification Pack
- Specifications:
  - Solution Soak Time: Metric: 1-3 h - Adjusted for alloy & thickest section; verified via thermocouple survey.
  - Artificial Aging Time: Metric: 4-8 h - Adjusts per required hardness; verified with eddy-current or hardness testing.
  - Maximum Load Weight: 1500 lb (680 kg) - Hearth rating limit; heavier batches split into multiple cycles.
  - Quench Temperature Range: 149-203 °F (65-95 °C) - Tank temperature ±2 °C with 1.5 m/s agitation.
  - Solution Temperature Range: 959-1004 °F (515-540 °C) - Programmed per ASTM B917/B918 with PID-controlled ramp/soak.
  - Artificial Aging Temperature: 320-392 °F (160-200 °C) - T5 direct-age or T6 after quench, per alloy data.
  - Furnace Uniformity: 5.4 °F (3 °C) - AMS 2750 Class 2 compliance; TUS & SAT documented.
  - Certifications & Standards: AS9100D, ISO 9001, AMS 2770, ASTM B917 - Furnace calibration, load charts, and traceable CofC included.
  - Quench Transfer Time: 10 s - Door-to-tank shuttle meets NADCA guidelines for ≤25 mm sections.
  - Mechanical Properties (A356 T6): UTS ≈ 270 MPa, YS ≈ 240 MPa, Elongation ≈ 8 % - Typical from ASTM E8 tensile bars; destructive tests performed per lot.
  - Quench Media: Water, 10 % glycol-water - Glycol blend used to moderate quench severity for heavier cross-sections.
  - Maximum Part Envelope: 48L x 40W x 40H in (1200L x 1000W x 1000H mm) - Basket clearance; taller parts can be racked vertically.
  - Typical Hardness Increase: Metric: 30-50 % - Example: A356 from ~HB 60 to ~HB 95 verified via hardness coupons.
  - Primary Equipment: 2 electric forced-air solution furnaces, 1 forced-air aging oven, Stainless agitated quench tank, Automated load/unload shuttle - Equipment calibrated quarterly; data is logged to MES under AS9100D.

### Tooling & Die Design

Thixocast engineers and fabricates proprietary dies in-house for semi-solid aluminum casting, leveraging mold-flow simulation, globular-flow gating, and advanced EDM/HSM techniques to eliminate porosity and flash. Constructed from hardened H-13 or other specialized tool steels, multi-cavity tools up to 1 000 × 600 × 500 mm undergo precise CNC/EDM machining, polishing, and CMM validation. Optional nitriding or die coatings extend service life to 250 k–500 k shots. The entire design-to-production cycle, including try-outs, typically completes in 12–16 weeks, ensuring a robust, high-yield die optimized for Thixocast’s semi-solid process.

- Process: Tool & Die (Fixtures & Gages)
- Highlights: Proprietary oversize gates & tuned vents sized for high-viscosity semi-solid aluminum flow, H-13 steel dies rated for 250 k–500 k shots; periodic re-polish or nitriding further extends life, Multi-cavity, slide & lifter solutions eliminate disposable cores for repeatable parts, In-house mold-flow simulation & end-to-end CAM/EDM workflow compress lead times to ≤16 weeks, Precision ±0.013 mm cavity accuracy with ≤0.4 µm Ra polish reduces flash & post-processing
- Subprocesses: High-Speed Die Machining, Sinker EDM, Wire EDM, Tooling Maintenance & Refurbishment, Die Design Consulting
- Specifications:
  - Number Of Cavities Supported: Metric: 1-8 cavities - Actual cavity count determined by part mass & machine shot weight; micro-parts (<25 g) may allow higher counts.
  - Maximum Die Size: 23.6L x 39.4W x 19.7H in (600L x 1000W x 500H mm) - Larger die sets evaluated case-by-case against press envelope and crane capacity.
  - Expected Tool Life: Metric: 250000-500000 shots - Based on A356/A357; optional nitriding or coatings can extend beyond 500k shots.
  - Cavity Surface Finish: Metric: 0.4-1.6 µm Ra - SPI / NADCA textures or EDM matte available; finer polish to ≤0.4 µm Ra on request.
  - Lead Time – New Tooling: 12-16 weeks - Includes design, steel procurement, machining/EDM, heat-treat, try-out, & CMM validation; expedite possible case-by-case.
  - Tool Steel Grades Supported: H-13 hot-work tool steel, P20 pre-hardened tool steel, S7 shock-resistant tool steel - Grades held in inventory; alternative or higher-alloy steels sourced on request.
  - Dimensional Accuracy (Cavity): 0.013 mm - Equivalent to ±0.0005″; ground shut-offs keep flash <0.010 mm.

### Precision CNC Machining

Thixocast’s dedicated CNC department transforms near-net thixocast blanks and other aluminum forms into fully finished components in a single facility. By leveraging minimal machining stock from the semi-solid casting process, cycle times and tooling wear are significantly reduced. Nine high-speed 3-/4-axis mills with rotary tables, through-spindle coolant, Renishaw probing, and automated pallet changers hold ±0.025 mm true-position and 0.8 µm Ra finishes. Lights-out scheduling and real-time SPC compress cast-to-machined lead time to 1–2 weeks for aerospace and medical customers. All machining data is recorded in an AS9100D-compliant MES, ensuring full traceability for PPAP/FAI and seamless integration with Thixocast’s end-to-end manufacturing solutions.

- Process: CNC Machining
- Highlights: ±0.025 mm (±0.001") positional accuracy verified on Hexagon CMM; CpK ≥ 1.67, Work envelope 1 000 × 600 × 500 mm; rotary 4th-axis Ø ≤ 400 mm enables multi-face machining in one setup, 3- and 4-axis Haas VF-4SS / UMC-500 and Okuma GENOS VMCs running 20 k rpm for high-speed aluminum cutting, Renishaw in-process probing streams SPC data for continuous lights-out runs, Typical secondary-machining lead time 1–2 weeks from casting release, Synergy with near-net shape thixocast parts reduces stock removal, cutting cycle times and tooling costs, Rapid prototyping supported (1–10 parts) through flexible fixturing before scaling to mass production, All final dimensional checks logged in AS9100D system for complete part traceability and PPAP/FAI documentation
- Subprocesses: 4th-Axis Milling, Automated Pallet Machining, In-Process Probing
- Specifications:
  - Machining Axes: 3-axis milling, 4-axis simultaneous milling, Rotary 4th-axis Ø ≤ 400 mm - Supports multi-face geometry in a single setup.
  - Minimum Drilled Hole Size: 0.02 in (0.5 mm) - Limited by tooling diameter and spindle speed parameters.
  - Production Scale: Prototype (1-10 parts), Short Run (11-500 parts), Medium Run (501-10000 parts), Mass Production (10001+ parts) - Covers everything from 1-off prototypes through mass production.
  - Maximum Part Size: 20L x 39W x 24H in (500L x 1000W x 600H mm) - Reflects machine travel envelope for typical VMC setups.
  - Material Compatibility: Aluminum A356 & A357 castings, Aluminum 6061 billet blocks, Aluminum 7075 billet blocks, Stainless 17-4 PH fixtures - Primarily focused on aluminum; steel/stainless are typically for secondary ops or fixturing.
  - Lead Time – Secondary Machining: 1-2 weeks - Typical queue from casting release to completed machining.
  - Dimensional Tolerance (Routine): 0.001 in (0.025 mm) - ±0.010 mm achievable on critical bores; verified under AS9100D procedures.
  - Minimum Milled Feature Size: 0.008 in (0.2 mm) - Micro-features require high-speed end mills and stable fixturing.
  - Primary Equipment: 9 × Haas VF-4SS & UMC-500 VMCs (20 k rpm, through-spindle coolant), 1 × Okuma GENOS VMC, Automated pallet changer cells for lights-out machining, Renishaw OMP60/OTS probing and tool setting - Optimized for high-speed aluminum cutting and unattended production.
  - Surface Finish (As Machined): Metric: 0.8-1.6 µm Ra - Finish cuts or polish can achieve <0.4 µm Ra.
  - Inspection Capability: Hexagon DCC CMM 1 000 × 700 × 600 mm, SPC reporting CpK ≥ 1.67 - Measurement data is stored in a central MES for AS9100D-compliant traceability.

### Finishing, Coating & Assembly

Thixocast provides a single-source solution for post-processing and final assembly of aluminum castings. In-house capabilities include bead-blasting, vibratory deburring, ultrasonic DI cleaning, and dimensionally controlled assembly benches. NADCAP-approved coating partners extend the range of finishes: anodizing, chromating, powder coating, e-coating, and plating. Parts requiring hardware insertion, helium leak tests, or torque verification can be completed on dedicated assembly lines, then packaged with full AS9100D traceability. This integrated approach cuts total lead time to 1–3 weeks, delivering turnkey, ready-to-install parts under a single purchase order.

- Process: Surface Treatment & Finishing
- Highlights: Ra ≤ 3 µm pre-coat surfaces via bead-blast and 300 L vibratory tumbling, Type II/III anodize, chromate, powder, e-coat, nickel/chrome—NADCAP traceable, Installs Helicoils, PEM studs, bushings, O-rings, and mild electromechanical assemblies, Helium leak-test ≤1×10⁻⁵ sccs, ISO-6789 torque verification ±4 %, and final in-house QC, Coating thickness ±5 µm verified by on-site XRF; adhesion and salt-spray tests archived, Clean-pack: ultrasonic wash, ESD/VCI packaging, barcodes, and custom foam or tray kitting, Typical cast-to-finish lead time 10–14 days (including outsourced coating); assembly in 3–7 days, Single-PO logistics with full AS9102 FAI/PPAP documentation and CofC
- Subprocesses: Light Mechanical Assembly, Electromechanical Assembly, Helium Leak Testing, Torque Verification (ISO 6789), ESD Packaging & Traceability
- Specifications:
  - Coating Adhesion & Corrosion Standard: ASTM D3359, ASTM B117 336 h salt-spray pass - Witness coupons each lot; archived with CofC.
  - Hardware Types Installed: PEM self-clinching studs/nuts, Helicoil & key-locking inserts, Oilite bushings, Dowty & O-ring seals - Other specialty hardware on request pending feasibility.
  - Maximum Part Weight: 55 lb (25 kg) - Blast turntable/assembly bench rating. Heavier parts processed case-by-case.
  - In House Surface Roughness After Blast: Up to 125 RMS (Up to 3 µm Ra) - Glass-bead media at ~80 psi; profilometer-checked per shift.
  - Assembly Envelope: 16L x 24W x 24H in (400L x 600W x 600H mm) - Larger assemblies evaluated case-by-case for fixture access.
  - Primary Equipment: 2 pressure-blast cabinets, 300 L vibratory finisher, Crest ultrasonic washer, Heated drying tunnel, DeFelsko XRF thickness gauge, ISO-9001 clean inspection bench - New in 2023; all gauges are ISO 17025-calibrated.
  - Torque Accuracy: 4 % - ISO 6789 certified drivers; data logged to MES.
  - Cleanliness Standard: ISO 16232 level 10 (optional hydraulic cleanliness) - Ultrasonic DI wash followed by particle count on request.
  - Maximum Leak Rate: 0.00001 sccs - Helium mass-spec testing at 1×10⁻⁵ std cm³/s or better.
  - Maximum Part Size (In House): 16L x 24W x 24H in (400L x 600W x 600H mm) - Cabinet capacity for blasting/deburring. Larger parts may be outsourced.
  - Lead Time – In House Finish: 2-3 business_days - Bead blast, tumble, clean, final QC. Often overlaps machining queue.
  - Anodize Thickness (Type III Hard): Metric: 25-75 µm - MIL-A-8625 Type III. Hard black or clear for wear surfaces.
  - Lead Time – Outsourced Coatings: 5-10 business_days - Transit, queue, coat, cure, and re-inspect. Often parallel to sub-assembly tasks.
  - Plating Thickness (Ni / Cr): Metric: 5-20 µm - ±2 µm control; XRF spot-check on critical surfaces.
  - Anodize Thickness (Type II): Metric: 10-25 µm - MIL-A-8625 Type II, dyed or clear. Seal optional.
  - Documentation Supplied: AS9102 FAI or PPAP Level 3, CofC with torque/leak data, Barcode pack-list - All records stored electronically for 15+ years.
  - Maximum Assembly Weight: 55 lb (25 kg) - Lift-assist bench capacity; heavier handled via forklift or outsource.
  - Powder Coat Thickness: Metric: 60-120 µm - Verified per ASTM D1186; cure per resin supplier specs.
  - Vibratory Tumble Finish: Metric: 1-2 µm Ra - Ceramic media cycle 2–4 h; deburrs edges for uniform finish.
  - Lead Time – Assembly & Pack: 3-7 business_days - Hardware lead time + final inspection queue. Can overlap finishing.

## Certifications

- North American Die Casting Association (NADCA) Membership (Type: Membership; Authority: North American Die Casting Association (NADCA); Status: Active; Scope: Corporate membership in NADCA demonstrating industry engagement; URL: https://www.diecasting.org)
- AS9100D (Type: Certification; Authority: International Aerospace Quality Group (IAQG); Status: Active; Scope: Manufacturer of High Integrity and Structural Aluminum Parts using Semi-solid Thixocasting and Machining.; Issue date: 2024-03-22; Expiration date: 2027-03-21; URL: https://www.sae.org/standards/content/as9100d/)
- ISO 9001:2015 (Type: Certification; Authority: International Organization for Standardization (ISO); Status: Active; Scope: Manufacturer of High Integrity and Structural Aluminum Parts using Semi-solid Thixocasting and Machining.; Issue date: 2024-03-22; Expiration date: 2027-03-21; URL: https://www.iso.org/iso-9001-quality-management.html)

## Industries Served

- Aerospace & Defense: Thixocast, Inc. manufactures high-precision, lightweight aluminum components using semi-solid thixocasting and heat treatment for aerospace and defense applications, including aircraft structural parts and engine components, ensuring compliance with AS9100:D standards for mission-critical performance.
- Automotive & Transportation: Thixocast, Inc. produces durable, near-net shape aluminum parts with integrated CNC machining for automotive and transportation sectors, such as EV inverter housings, suspension knuckles, and battery enclosures, enhancing vehicle performance and efficiency through lightweight design.
- Medical Devices & Healthcare Equipment: Thixocast, Inc. supplies precision-machined aluminum components for medical devices and healthcare equipment, including surgical instruments and diagnostic systems, leveraging biocompatible materials and stringent quality controls to meet industry standards.
- Industrial Machinery & Heavy Equipment: Thixocast, Inc. fabricates robust, high-integrity aluminum parts for industrial machinery and heavy equipment, utilizing semi-solid thixocasting and precision machining to deliver components such as housings and brackets that withstand harsh operational environments.
- Marine & Shipbuilding: Thixocast, Inc. manufactures corrosion-resistant, precision aluminum components for marine and shipbuilding applications, including engine parts and structural fittings, ensuring durability and performance in challenging saltwater environments.
- General Manufacturing: Thixocast, Inc. offers versatile design, fabrication, and assembly services for a broad range of manufacturing projects, delivering custom semi-solid thixocast aluminum parts with integrated machining and finishing to meet diverse client specifications.

## Facilities

### Lakewood Headquarters & Plant

The 31,000-ft Lakewood headquarters integrates billet casting, four semi-solid die-casting presses, CNC machining, heat-treat furnaces, and AS9100-certified inspection, ½ mile from I-70 and 30 min to Denver International Airport, enabling rapid inbound materials and outbound shipments.

- Type: manufacturing_facility
- Headquarters: Yes
- Email: info@thixocast.com
- Phone: +1 303-781-0234
- Address: 5567 W 6th Avenue, Lakewood, CO 80214, USA

## Verification Status

- Business Entity: Verified 5/24/2025
- Technical Capabilities: Verified 7/3/2025
- Locations & Facilities: Verified 7/3/2025
- Reviews & Ratings: Not yet verified
- MFR.ID Created: 5/24/2025
- Last Updated: 5/14/2026