Thixotropic injection molding barrel assembly

A method of thixotropic injection molding, the method comprising steps of:

• inserting magnesium chips into a screw chamber of a barrel of a thixotropic injection molding barrel assembly via a loader, the barrel having a first section and a second section removably connected to the first section;
• rotating a screw in the screw chamber and heating the barrel thereby compressing and shearing the magnesium chips so the magnesium chips melt into a thixotropic slurry;
• shifting the screw to a retracted position such that some of the thixotropic slurry is forced past a check ring on the screw and enters an injection chamber portion of the screw chamber in the second section;
• and
• shifting the screw to a forward stroke position such that the thixotropic slurry is injected into a mold from the injection chamber portion.

A thixotropic injection molding barrel assembly comprising:

• a loader including an opening for receiving magnesium chips;
• a barrel including:
• a first section configured to be removably connected to the loader;
• and
• a second section configured to be removably connected to the first section opposite the loader and including an integrated end cap, wherein the loader, the first section, and the second section form a screw chamber;
• a screw positioned in the screw chamber and including:
• a rotatable shaft;
• a helical screw flight on the rotatable shaft;
• a tip removably connectable to the rotatable shaft;
• and
• a check ring positioned on the tip;
• a nozzle connected to the second section;
• a nozzle cap retaining the nozzle on the integrated end cap;
• a first heating element encircling the first section and configured to heat the first section;
• and
• a second heating element encircling the second section and configured to heat the second section,
• wherein the second section forms an injection chamber portion of the screw chamber when the shaft is in a retracted position.