You will discover many interesting topics relating to the powertrain of e-mobility and integrated cooling channels with MAGIT in the Workshop No.2 on 14 March 2024 at the Materials Testing Institute of the University of Stuttgart on the Stuttgart-Vaihingen campus.

Download programme: Programme-PDF [3,4 MB]

Link to Cyberjoin:

Aalener Gießereikolloquium 2024

In 2024, we will be back again with our MAGIT power module at the HS-Aalen on 16-17 May.

Programme and registration:
Aalener-Giesserei-Kolloquium-2024.pdf [236 KB]

Euroguss 2024

Thank you for your visit and we look forward to welcoming you again in 2026 at our new booth in Hall 5 No. 5-113!

The new process

Magnesium and Aluminium Gas Injection Technology

MAGIT is the new gas injection technology for creating completely new die casting applications such as power electronic housings with integrated cooling lines and other hollow magnesium and aluminium die-cast structures.

This technology involves the still liquid melt at the core of the component being displaced into an opening overflow cavity during the cooling phase.




Our philosophy encompasses a holistic support and consultation service from component development and die design and construction to the actual die casting process.

Our experienced engineers assist you in using our new MAGIT gas injection process and the associated plant technology successfully in high-pressure die casting – from the outset, through each development stage of your component, planning and commissioning to process optimising.


Plant technology

The new MAGIT plant technology consists of all components which, together, are responsible for successful implementation of a reproducible process:

  • Stand-alone system for connection to existing die casting cells
  • Effective compressor unit:
    Efficient gas compression to over 500 bar
  • Integrated hydraulic supply:
    Supplies die modules with up to 250 bar
  • Integrated accumulator modules:
    Providing two pressure levels for melt displacement
    and holding pressure
  • Real-time control:
    For reproducible gas injection within 5 ms
  • Number of cavities:
    Single or dual cavity plants are available

MAGIT 2-cavity power module

Diagram of MAGIT plant technology


Component development

Gas-compatible component design

  • Functional integration (avoidance of friction stir welding or inserts)
  • Optimum duct dimensioning and course
  • Integration of gas brakes
  • Design of duct connection geometries (screw bosses, ribbing)



Solidification and filling simulation

  • Casting layout with MAGMA software
  • Simulation of solidification phase, taking gas injection into consideration
  • Theoretical determination of duct wall thickness
  • Determination of cavity volume


Die concept

Creation of die concepts

  • Specification of ideal injector positions and overflows
  • Definition of component position in die
  • Dimensioning and positioning of gate valve
  • Layout of overflow cavity


Injector technology

MAGIT injector

The injector technology, which enables the reproducible introduction of gas to the interior of the die-cast component, is decisive for the success of this gas injection technology.

The injection process for the gas and, consequently, the quality of industrial-scale die-cast components can only be assured with the injectors appropriate for use with MAGIT.


Die modules

Die-adapted injection and overflow cavity modules

consisting of the following:

  • Connection plates with standardised hydraulic, cooling water, gas supply and sensor connections
  • Different injector and gate valve lengths adapted to suit die
  • Tool inserts for overflow and injection duct


Process optimizing

Process optimising of MAGIT process following commissioning and installation of new dies

  • Optimising of gas injection
  • Optimising of injector and gate valve opening and closing times
  • Adaptation of overflow volume
  • Optimising of clearing and holding pressure


Component testing

Broad range of diverse component tests

  • Testing pursuant to LV 124
  • Vibration testing (on 24 KN and 70 kN shakers)
  • Static and dynamic burst pressure testing
  • Flow testing (oil, glycol, water)
  • Climatic chambers
  • Leak tests
  • Pressure loss measurements (air, oil, glycol, water)
  • Pulsation tests (air, hot air, oil, glycol, water)


Service & training

We offer complete post-commissioning support with the following:

  • Operator training
  • Prompt replacement and wear part supply
Support during maintenance and service work
  • Service training



European Commission


This project has received funding from the European Union‘s Horizon 2020 research and innovation programme under grant agreement No 950866

Currently, the following companies are working together in the context of the European Fast Track to Innovation (FTI) support and funding programme:

Prof. Dr.-Ing. Lothar H. Kallien
Aalen University
Beethovenstr. 1
D-73430 Aalen

René Wagner
CEO / Inhaber
Nellen 12
CH-9246 Niederbüren

Harry Vangansewinkel
Technical Sales Engineer
Surtechno nv
Siberiëstraat 5
B-3900 PELT

TiK-Technologie in Kunststoff GmbH
Siemensstr. 21
D – 79331 Teningen

We are member of the Innovation Network Gas Injection in Die Casting

Interesting facts for you




Franz Krall

Sales & Technology

Mobile: +49 173 8525112

Lärchenwaldstrasse 18
4820 Bad Ischl

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