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Institutional analysis forecasts explosive growth in magnesium alloy demand as multiple manufacturers target commercial mass production of humanoid robots in 2026.

Magnesium stands out for its superior lightweighting compared to aluminum, combined with high damping, electromagnetic shielding, and excellent heat dissipation. These properties help extend runtime, reduce vibration, protect electronics, and manage heat in compact, high-performance robots.

The material is already in widespread use in many robotics platforms.

(Source: East Money) Demand projections are substantial: Industry estimates put magnesium alloy usage at roughly 12 kg per humanoid robot.

At 1 million units per year → 12,000 tons of demand

At 10 million units per year → 120,000 tons of demand

At 100 million units per year → 1,200,000 tons of demand (more than 2025 global primary production)

With several robot makers planning volume production in 2026, magnesium is shifting from niche applications to an important structural material. Advanced forming processes, including large-scale semi-solid magnesium (thixomolding) technology, are expected to support the production of complex, high-strength components at scale.

This emerging demand creates new opportunities across the magnesium supply chain and positions the alloy as a key enabler in the coming wave of commercial humanoid robotics.

In the coming years it’s going to unlock a massive opportunity for the foundry industry.

Huadi Technology, a subsidiary of GAC Group, has successfully completed trial production of the rear Gigacasting for GAC’s first mass-production model. Developed in close collaboration with GAC Group’s Vehicle Development Research Institute, for these trials they used the 9000-ton machine from Guangdong Hongtu and a self developed mold.

The component has passed full production-line verification and met all the performance targets across dimensional accuracy, mechanical properties, and surface quality, fully qualifying it for volume production and vehicle assembly.

This achievement marks a major step forward for Huadi Technology. Large-scale one-piece die casting allows automakers to replace dozens of stamped and welded parts with a single high-strength aluminum casting. The result is lower vehicle weight, fewer assembly steps, reduced cost, and improved structural performance.

The next step for GAC is to install two 9000 ton machines at its own production base in Guangzhou operated by their subsidiary Huadi Technology.

Months ago they published a public tender which was awared to Haitian.

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Haitian Zhisheng in collaboration with Waffer Technology and Chongqing University received the International Magnesium Association (IMA) Award of Excellence for Process for the HMG7000U twin-screw 7,000-ton thixomolding machine.

The world’s first and largest dual-barrel machine (70,000 kN clamping force, dual Φ180 mm screws, >38 kg injection weight, millisecond closed-loop control). It targets large integrated magnesium structural parts such as vehicle bodies, frames, and door inner panels — moving Mg from small components to mainstream structural use. The associated Waffer R&D Centre for Lightweight Materials and Thixomolding Magnesium Alloy Application Centre was inaugurated in November 2025. Full article here.

Bida New Energy, a subsidiary of Xinbo Shares, showcased magnesium alloy components for robots, including joint structural parts such as the robot upper arm outer shell, upper arm inner shell, and elbow connecting rod. The upper arm inner and outer shells, along with the elbow connecting rod, are all made of AZ91D magnesium alloy and formed in a single step using 350-ton semi-solid thixomolding equipment.

The company is currently fully advancing the construction of 17 die-casting production lines, of which 15 thixomolding lines. 9 of them have already been officially commissioned and put into operation. Once all production lines are completed and operational, Bida New Energy’s semi-solid casting capabilities will cover a full range from small precision components to medium and large structural parts.