Megacasting at Handtmann: A Path is Made by Walking It

Partner

Foundry Corporate News

29. May 2024

Albert Handtmann Metallgusswerk GmbH & Co. KG has secured a leading position in the casting of large structural and body components with the acquisition of Carat 610 megacasting machine from Bühler AG.

Reading time: min

This bold step opens new avenues in manufacturing and demonstrates the company's commitment to developing innovative solutions. The introduction of megacasting, a highly relevant topic in the foundry industry, enables the production of highly integrative and complex parts in a single casting process. This technology, implemented by Handtmann as the first Tier-1 supplier in Europe, offers numerous advantages, including reduced production time and costs, as well improved structural stability of the components. The associated investments include infrastructure adjustments and the acquisition of the high-performance Bühler Carat 610 machine at the Biberach site.

Two More Megacasting Machines Planned

The company has the capacity to install two additional megacasting machines to meet growing demand. Handtmann already has orders: "We have two series orders with production starting in 2026, with pre-series production beginning in 2024," says Stefan Kneer, Head of Engineering and Business Development at Handtmann. One of the new orders involves a high-voltage battery housing. At 2.10 meters in length, this ventures into dimensions previously unimaginable for die casting.

The Decision to Enter Megacasting as a Tier-1 Supplier

Presentation of the innovation study rear carriage (left: Andreas Würzer, right: Stefan Kneer)

The major advantage of megacasting lies in the ability to simplify assemblies. By utilizing the design freedom of die-cast components, individual parts are substituted, and functions integrated, eliminating critical joining processes in manufacturing. This results in significantly reduced cycle times and space requirements in production. Consequently, parts produced with megacasting are much cheaper to manufacture and generally offer higher structural stability compared to complex assembled units.

Component Testing within Innovation Projects

Before deciding to invest in megacasting, Handtmann conducted component developments as part of innovation projects. One component, for example, replaced a conventional vehicle module with 97 individual parts. The die-cast part met all requirements for rigidity, strength, and crash behavior.

Development process for die-cast components

"We have acquired deep development expertise in recent years, allowing us to engage with our customers in very early development phases. We start with topology optimization, which is essential for developing a structural die-cast component. Once the initial CAD data is created, casting simulations begin. Particularly with large parts, castability must be considered from the outset," says Kneer. Handtmann, together with partner companies, has realized pre-development projects not only for rear structures but also for front structures, tailgates, and battery systems.

Development of aluminium content per vehicle (source: Ducker)

Well-Equipped for the Future

Beyond megacasting, Handtmann is advancing other innovation projects and continually developing new parts such as e-components or structural parts, produced on over 99 die-casting machines. "Megacasting is heavily trending. However, our customers have also recognized that utilizing the benefits of die casting across the entire vehicle can achieve savings. Driven by the need for simplification and weight reduction, especially in e-mobility, we expect a further significant increase in the aluminum die-casting share per vehicle. This presents unprecedented opportunities for the casting industry. We are leveraging these not only with innovative lightweight design but also by working on process developments and alloy developments. The path is paved; we must walk it and seize the opportunities," concludes Kneer.

Thus, the company remains a key partner in the automotive supply industry, committed to innovation and collaborating with customers on new projects.

With over 150 years of tradition and expertise in metal casting, extensive technical competence, and a strong international network, Handtmann once again demonstrates its ability to transform complex challenges into effective solutions.

For more information, visit www.handtmann.de.

About Handtmann - Leading Technology Across Five Generations

Albert Handtmann Metallgusswerk GmbH & Co. KG is a strategic system partner for the automotive industry in the field of light metal casting (aluminum and magnesium casting) for powertrain, chassis, and bodywork.

The internationally operating company, headquartered in Biberach an der Riss, has a 150-year history of success and has proven through long-standing experience and expert knowledge its ability to transform complex challenges into viable solutions. The over 2,300 employees in the German plants in Biberach and Annaberg, the Slovakian plants in Košice and Kechnec, and the Tianjin plant in China, generated a turnover of around 597 million euros in the 2023 fiscal year.

Whether die casting or permanent mold casting, Handtmann's product strategies and problem-solving processes are interlinked:

Utilize engineering competence early in the development process.
Combine customer and Handtmann competencies in a targeted manner.
Find a common level for solving project tasks through interdisciplinary dialogue.
Complex mechanical processing and component and system assembly complement a consistent product strategy.

More information at www.handtmann.de.