Seres and Boao Mei Aluminium Launch World's First Mass-Produced Semi-Solid Magnesium Alloy CCB, Ushering in a New Era of Lightweighting for AITO

On May 18, Seres Group Director and Vice President Kang Bo officially announced that Seres and Boao Mei Aluminium have successfully launched the world's first mass-produced semi-solid process magnesium alloy body component. The newly manufactured CCB (cockpit cross beam) fills a critical industry gap and marks a significant step forward in extreme lightweighting for new energy vehicles.

Magnesium alloy semi-solid forming technology has long been seen as the ultimate goal of lightweighting, delivering substantial weight reduction without sacrificing mechanical performance. However, the technology has faced major barriers: high capital investment, extreme process complexity, and a lack of proven mass-production precedents. To overcome these challenges, Seres and Boao Mei Aluminium formed a dedicated task force, running extensive trials covering material formulation, process optimisation, production line layout and batch stability control. Using the HMG3600 large-scale magnesium alloy injection moulding machine developed by Haitian Intelligent Metal, the team adopted semi-solid injection technology to eliminate shrinkage and porosity defects while achieving grain refinement and uniform microstructural distribution. A dedicated semi-solid magnesium alloy production line has now been established, reaching a stable capacity of 1,000 units per day.

The new semi-solid magnesium alloy CCB delivers significant weight reduction compared to conventional steel or aluminium structures. Based on comparable production data, a single unit typically weighs between four and five kilograms, achieving over 50 per cent weight reduction versus traditional steel components. Tensile strength is improved by 10 to 20 per cent relative to conventional processes, while fatigue resistance and corrosion performance are also significantly enhanced, meeting the high rigidity and safety standards required for structural body applications.

Seres has officially incorporated the semi-solid magnesium alloy CCB into the upgrade plan for its AITO model family. Beyond the weight reduction of this specific component, Seres has already achieved 20 kilograms of magnesium alloy content per AITO vehicle, and its one-piece die-cast magnesium alloy rear body structure consolidates 87 separate parts into a single component. With this latest breakthrough, Seres has now extended its lightweighting efforts from peripheral structures to core load-bearing components.

As competition in the NEV sector extends into materials science, lightweighting has become a core imperative for energy efficiency and range performance. With this mass-production milestone, Seres has not only strengthened its own product competitiveness but also provided a scalable industrial blueprint for the industry’s transition to magnesium alloy components. Looking ahead, Seres says it will continue to deepen strategic partnerships across its supply chain, expanding applications for semi-solid magnesium alloy technology across body, chassis and drivetrain systems.