More complex geometries, high dimensional accuracy, and cost-efficient large-scale production are expected. The 4-plate high-pressure-die casting mold technology opens up new possibilities: by adding an additional parting plane to the tool design, it enables the efficient realization of complex contours, undercuts, and slider movements. Particularly for large structural components and automated processes, the 4-plate design offers clear advantages over conventional tooling concepts and is considered a key technology for the next generation of high-precision die cast parts.
Innovative Tooling for Complex Parts Now Ready for Series Production
Toolmaking specialist KRÄMER+GREBE, based in Biedenkopf, has reached a new milestone with the successful implementation of a 4-plate high-pressure-die casting mold on a 5,700-ton die casting machine. On March 14, 2025, the team demonstrated that this complex tooling concept is not only technically feasible but fully ready for series production. Especially for demanding aluminum components with thin walls and functionally optimized geometries, this technology provides entirely new options—while also improving economic efficiency and process reliability.
At the heart of the development lies a fourth tool plate, which enables additional parting lines and gating positions, while also allowing the controlled detachment of the gate system during die opening—a highly sensitive process step requiring exceptional precision and innovation in tooling design. KRÄMER+GREBE successfully integrated this step into a reliable production process through targeted technical solutions.
Efficiency Through Function-Oriented Part Design
The 4-plate technology makes it possible to place multiple direct gates directly onto functional areas of the part—rather than relying solely on flow-path-optimized designs. This allows for reduced wall thicknesses and flow paths, improved solidification control, and the prevention of shrinkage cavities. In practice, this means up to 20% weight reduction with no loss in function, shorter cycle times, and lower material consumption.
The proximity of the gates to the part also enables early separation, minimizing the need for post-processing and increasing production speed. The projected area (sprue spread) can be reduced, as the gating system is located in the “shadow” of the part—an important advantage for multi-cavity high-pressure-die-casting and large-scale Giga Casting components.
Innovations in Cooling, Maintenance, and Process Control
To meet the high demands of temperature control, KRÄMER+GREBE developed cost-efficient wear sleeves as well as 3D-printed cooling sleeves, which ensure precise cooling of each gate pipe—an essential factor in maintaining consistent part quality. The system is further enhanced by a hydraulically controlled holding mechanism, which prevents uncontrolled movement of the separated gating system and ensures safe and repeatable removal from the die casting machine.
Another highlight: the fourth plate features an integrated cleaning and maintenance function, allowing worn components to be serviced or replaced directly at the machine—an important contribution to process stability and equipment availability.
A Future-Proof Platform for Scalable Series Production
With this new high-pressure-die casting concept, KRÄMER+GREBE addresses the challenge of manufacturing large, complex parts economically, reproducibly, and in consistently high quality. The high-pressure-die casting mold is designed for maximum robustness, ease of maintenance, and long service life. Especially in high-pressure die casting—where dies must withstand extreme thermal and mechanical loads—every part must be cast with repeatable precision.
The result is a scalable, forward-looking tooling platform that makes existing die casting machines more productive—whether for large individual components or the parallel casting of multiple parts in a single shot. The 4-plate technology saves material, time, and cost—and paves the way for a new generation of high-performance aluminum die cast products.
The KRÄMER+GREBE team proudly looks back at the moment of the first successful casting—marked by the distinct “crack” of a clean gate separation and a part that met all expectations. With this achievement, the experts from Biedenkopf have not only solved a technical challenge but also made a significant contribution to the future of modern die casting.
For further information about the implementation and potential applications, the expert team at KRÄMER+GREBE is available for consultation.
