MAGIT technology enables the direct production of hollow, functionally integrated structures in aluminum and magnesium die casting without cores or downstream joining processes. After the mold is filled, gas is injected into the still-liquid melt and displaces material into a secondary cavity. This creates stable hollow channels that are supported by gas pressure during solidification. The process originates from plastic gas injection and has been further developed for metallic melts.
Advantages for design and manufacturing
MAGIT significantly reduces material and manufacturing costs, shortens cycle times, and enables new design freedoms. Media-carrying channels can be integrated directly into the casting in a flow-optimized manner, which improves heat transfer and enables more compact, higher-performance components. The elimination of components such as pipes, seals, or welded joints reduces assembly costs and logistics costs.
Example: DC-DC converter heat sink
A Bosch series part demonstrates the potential: Replacing a glued-in aluminum tube with a cast cooling channel saves around 250 g in weight and approximately 20% in costs. At the same time, thermal efficiency is significantly increased because the channel can be precisely adapted to the heat transfer surfaces.
Development and outlook
Since 2004, the technology has been developed to series production readiness at Aalen University and by industrial partners. MAGIT can now also be applied to other metals such as copper, as well as to die casting and low-pressure casting, where it can achieve low-porosity structures and complete shrinkage compensation. With its combination of process stability, design freedom, and resource efficiency, MAGIT sets a new standard for functionally integrated die-cast parts in automotive engineering, electronics, furniture construction, and consumer goods design.
Tip: For more information on this topic, attend the presentation at the German Die Casting Day during EUROGUSS 2026
Date: Mi., 14.01.2026, 14:00 - 14:30
Location: Room St. Petersburg, NCC Ost
