Magnesium Casting Machining | Magnesium Machining Specialists

ShearXL is one of the UK’s most experienced magnesium machining specialists, manufacturing precision components from both castings and solid billet for customers across the UK and internationally.

From Formula One and aerospace to automotive and specialist engineering, we support applications where precision, reliability and engineering expertise are critical.

With machining capacity up to 1m³, we’re equipped to manufacture everything from intricate precision components to large, complex magnesium parts.

Our capabilities

Precision machining of magnesium castings
Precision machining from solid billet
Components up to 1m³
Prototype and production quantities
3, 4 and 5-axis CNC machining
Inspection and quality assurance
Dedicated fast-turnaround machining cell

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Why choose a specialist magnesium machining partner?

While magnesium offers significant performance benefits, it also requires specialist machining techniques that differ from conventional engineering materials.

ShearXL has developed dedicated machining processes specifically for magnesium, including specialist coolant and swarf management, enabling components to be machined safely, consistently and efficiently.

With relatively few subcontract machine shops offering dedicated magnesium machining, choosing an experienced partner can help reduce technical risk while ensuring consistent quality from prototype through to production.

Industries We Support

ShearXL has built an excellent reputation machining customer supplied magnesium castings for Formula One and high-performance motorsport applications, where every gram matters.

From gearbox casings and structural components to complex prototype parts, our specialist magnesium machining expertise helps deliver lightweight components without compromising precision or quality.

Our specialist magnesium machining expertise also supports historic motorsport projects, where preserving the integrity of original magnesium components is equally important.

Read our Riley Technologies magnesium machining case study →

Magnesium continues to be specified for selected aerospace and defence applications where reducing weight is critical.

ShearXL machines magnesium components for customers requiring the precision, repeatability and quality demanded by these sectors, supporting both prototype development and production manufacture.

As part of The Shearline Group, our customers also benefit from access to wider aerospace manufacturing expertise, including AS9100-certified capabilities within the group.

As vehicle manufacturers continue to pursue lightweight designs and vehicle electrification, reducing component weight remains an important engineering objective.

ShearXL machines magnesium castings and billet components for automotive applications, delivering the accuracy and consistency required for demanding engineering programmes.

Beyond motorsport, aerospace and automotive, we machine magnesium components for a wide range of specialist engineering applications, including test and measurement equipment, scientific instrumentation and bespoke OEM products.

Customers value the combination of specialist magnesium machining expertise and the responsive, collaborative service we provide throughout their projects. From early technical discussions through to manufacture, our experienced team works closely with customers to help achieve the best possible outcome.

Combined with our large machining capacity of up to 1m³, our experience enables us to support a broad range of complex engineering applications.

Large Component Magnesium Machining

Our dedicated large-format 5-axis machining capability enables us to machine complex magnesium components up to 1m³

Machine spotlight

Matsuura MAM72-100H

5-axis horizontal machining centre
1,000 × 1,000 × 1,000 mm capacity
240-tool magazine
Renishaw probing

Review our full Plant List here

We don’t just machine magnesium! Did you know we also offer large component machining of aluminium, titanium and cast iron?

Frequently Asked Questions

Yes. A significant proportion of our magnesium work involves machining customer-supplied castings, from one-off development parts through to repeat production components.

Yes. We machine components from both magnesium castings and solid billet, depending on the application and customer requirements.

Our machining capacity allows us to machine components up to 1m³, enabling us to produce everything from intricate precision parts to large structural components.

Yes. ShearXL has a dedicated machining cell supporting the fast-turnaround demands of Formula One and high-performance motorsport.

This experience has enabled us to develop responsive manufacturing processes, allowing us to react quickly when lead times are critical while maintaining the quality standards our customers expect.

Yes. We regularly machine one-off prototype components, development parts and low-volume production, working closely with customers to support product development and validation before full production.

We regularly machine a range of magnesium alloys, with AZ31B being the most common grade for billet machining and RZ5 for castings.

If your application requires specific material properties, our engineering team can advise on the most suitable alloy. We can also provide material data sheets to help you select the most appropriate and cost-effective grade for your application.

Yes. With over 35 years of magnesium machining experience, we’re happy to discuss your project and recommend the most suitable manufacturing approach before production begins.

Ready to discuss your project?

If you’re looking for an experienced magnesium machining partner, we’d be pleased to discuss your requirements.

Whether you need machining from castings or solid billet, or you’re developing a new lightweight component, our engineering team can help.