Hayes Brake, a manufacturer of hydraulic high-performance bicycle disc brake systems, contacted Phillips to mold brake master cylinder components for an existing program. Magnesium was chosen for its light weight, exceptional strength, and molding advantages. The company contracted with Phillips Plastics Corporation to manufacture the magnesium injection molded base plate. Back To Top Versatile Material Magnesium can be used in higher temperature applications than plastics, and compared to engineering resins, magnesium offers a similar density, but provides strength and stiffness two times greater than that of thermoplastics. In addition, EMI and RFI shielding are inherent properties, as are heat transfer and electrical conductivity characteristics.
Magnesium is also a viable alternative to other metal alloys.
The lightweight and strength offered by magnesium injection molding were key to the following recreational customers utilizing this technology to improve its product. The brake company researched alloys to find one that was more ductile and less likely to fracture. The company determined that the alloy AM60B met product requirements better than the original alloy. This material is tough and is used in many structural applications, including automotive safety and crash management systems. Hayes Brake then concluded that AM60B is best processed via magnesium injection molding, which results in a lower porosity than die-casting.