Thixoforming, an innovative technique in which metals are formed in their semi-solid state, permits the cost-efficient production of components with improved properties and performance compared to conventional pressure die casting. Since this process is still relatively new, great technical advances can be expected in the near future. These advances should allow production of near-net-shape components with good mechanical properties, combined with low manufacturing cost. Due to the distinct thixotropic flow pattern of the semi-solid slurry, high production speeds similar to those of conventional pressure die casting can be achieved, yet the disadvantages of the latter are eliminated: thixoformed components possess a good combination of strength and ductility, and they are heat-treatable and weldable. The requirement for thixotropic flow behaviour is a particular microstructure in the semi-solid state. At the onset of forming, the solid phase of the material must exhibit a globular morphology, a feature that can be produced with a novel casting technique called New Rheocasting (NRC). Cast billets of several aluminium alloys and resulting microstructures show the feasibility of the chosen process variant. Constitutive models for the distinct flow behaviour of thixotropic aluminium alloys in the semi-solid state are derived with respect to temperature, strain rate and microstructure. Experimental techniques such as deformation tests, backward extrusion experiments, differential thermal analysis and quantitative metallurgy provide the necessary data to calibrate the materials models. For the implementation in a special-purpose FE software package, constitutive models for the thixotropic flow stress, the specific thixotropic flow stress, the specific heat capacity and the thermal conductivity of cast and wrought aluminium alloys in the semi-solid state are provided. For the optimization of the thixoforming manufacturing process these models were implemented in the FE software package ThixoForm. The simulation results were compared with industrial experiments and used for process control with the objectives of high-quality parts and maximum productivity.