Plastic and steel were once the staples in consumer electronics cases. Today, that doesn’t seem to have changed. However, many of the new electronic components that appear to have a lightweight plastic or strong steel casing actually contain neither. Today’s consumer electronics are largely made from a magnesium alloy.

the deception

Magnesium alloy materials closely resemble the special plastics used in electronic housings. The Thixomolding process can create magnesium alloy products that are much thinner than previous plastic and steel models. The alloy is often considered a space-age invention due to its ability to be molded into a very thin material. Magnesium products are finished with carbon fiber, plastic, and sand-based abrasive materials. The product is polished, polished and finished in several steps. Die-cast magnesium components can be painted using electrophoresis coating or powder coating processes. The pieces require a pre-treatment to ensure adherence. There are several production body structure applications that are painted, as well as first surface interior components. Magnesium alloy materials are cheaper due to their lower die casting and surface finishing costs. They are stronger than plastic and have better recyclability properties.

Plastic electronic components are created using the injection molding process which is similar to thixomolding. They can create very thin casings, but not very strong ones. Plastic is very versatile. It can be die to look like a metallic material or finished to get the same result. The finished product is very light, but does not withstand a drop test. The magnesium alloy won’t crack when dropped, but goes one step further to protect the components inside the case.

Applications

The best examples of uses for magnesium are laptops created by Apple. For example, they are thin enough to fit in a manila envelope. They look flimsy and are so light that users would use them if they were made of plastic. However, these portable personal computers are built from magnesium alloy. In the MacBook Air, the three pounds of compute consists of a magnesium frame and case. Other companies like Toshiba are using the alloy to create their own thin and light versions.

The fact that magnesium alloys have been created to retain many of the plastic characteristics is significant in itself. Consider the alloy as an improvement on the plastic case. Magnesium alloy materials add strength and damping capabilities to the thin molded material.