The committee has outlined several concrete plans to achieve its goals: 

Developing International Standards: Formulate an international version of the "Foundry Industry Cluster Standards".

• Conducting Global Research: Investigate the status of foundry clusters in various countries and regions and assist in their improvement.
• Sharing Chinese Experience: Systematically summarize the 40 years of development experience of China's foundry clusters.
• Promoting Academic Exchange: Regularly organize academic and technical exchange activities.

This move to share China's cluster development model represents a notable advancement in international industrial cooperation. In the future, China Foundry Association will closely collaborate with the World Foundry Organization (WFO) and other WFO member organizations, to efficiently and pragmatically advance the committee’s initiatives, thereby contributing more significantly to the sustainable development of the global casting industry.

2026 will mark the 40^th anniversary of China Foundry Association, foundry leaders, experts, enterprises, media around the world are invited to join the "40th Anniversary of China Foundry Association" celebration activities including the events Metal China/Diecasting China/Nonferrous China 2026, international foundry forum, etc. in Shanghai from May 5th-9th, 2026, to review the glorious journey, summarize development experience and look forward to a bright future.

Casting technology for lightweight construction – insights from BMW AG

The presentation by BMW attracted a great deal of attention: speakers Dr Hanss and Mr Arnold used the example of the rear axle carrier for the BMW iX3 in integral gravity casting to demonstrate how lightweight construction, low wall thickness, high rigidity, optimised crash behaviour and reduced noise can be combined in a single component. The development and production steps shown clearly demonstrated how consistently the car manufacturer BMW is now focusing on material-saving and functionally integrated casting solutions.

Large-scale casting in transition – prospects at Everllence SE

Marco Nagler offered a glimpse into the future of large-scale casting. He reported on positive momentum in the engine industry and on the new beginning for Everllence SE following its name change in the summer of 2025.

The company is increasingly focusing on key technologies such as hydrogen engines, future fuel solutions, retrofit concepts, carbon capture and large heat pumps. Further investments are planned for 2026, such as a large cleaning cell; and job advertisements for 25 foundry mechanics are running in parallel, underlining the growth strategy.

‘The fascination of casting’ in its purest form – Pinter Guss shows its range

With visible enthusiasm, Joshua Bissels, expert for digitalisation and future topics at Pinter Guss, presented extraordinary castings from his company. The spectrum ranged from diffusers for pilot boats and cooling plates for vacuum pumps in reactor plants to a completely redesigned cylinder head for an air-cooled boxer engine in a VW. The examples impressively illustrated how versatile modern foundry technology is today – technically sophisticated, aesthetically appealing and often central to safety-critical applications.

Experience research live

Once again, Fraunhofer IGCV presented itself as a place where research is not only discussed, but lived. The atmosphere in the experimental foundry and the discussions with scientists and practitioners showed that innovative spirit and implementation strength go hand in hand here. Many participants took this spirit with them, visibly motivated – and perhaps also with new ideas for their own projects.

Flexible furnace solutions for every foundry

From compact melting and dosing systems to in-cell solutions for large structural parts, from green sand moulding to die casting, StrikoWestofen has furnaces for foundries of all shapes and sizes. All of which will be available to view at the show via digital tours and expert discussions.

“Every foundry faces a different production challenge,” continued Peter Reuther. “Those producing small-scale, high-volume components need compact furnace systems that deliver consistent quality with minimal energy use.

“Others - especially in the EV sector - need to bigger, more complex castings. Our LeanMelter technology is designed precisely for that - enabling efficient melting within the die-casting cell, minimizing transfer losses and optimizing cycle times. All of which are vital to giant casting operations.

Digital tools keep a tight ship in the melt shop

Finally, visitors to the stand will also see how proven digital solutions such as Monitizer | DISCOVER, Monitizer | PRESCRIBE and Monitizer | REFILL MONITOR can add real value to melting, dosing, and entire casting cell operations - by turning data into actional insights for IIoT and AI-driven process optimization.

By tracking KPIs such as energy use, dosing accuracy and refill status, they help die casters minimise downtime, cut waste and run operations more efficiently. Together, StrikoWestofen and Monitizer give foundries the visibility and control to optimize every melt, dose and furnace refill.

Peter added: “Foundries need furnaces that last for decades, reduce CO2 footprint, lower costs, and strengthen resilience. Digital solutions that maximize those benefits. And a service provider that can flex solutions and support in a rapidly evolving world.

“At EUROGUSS 2026, we’re here to say, ‘whatever your need, we meet it’. And we look forward to demonstrating this at the show.”

Visit StrikoWestofen at the Norican stand at EUROGUSS to explore the shape of what’s next in efficient melting and dosing.

01. Strategic Positioning – From Catching Up to Leading the Industry

Driven by carbon peaking and carbon neutrality goals, EV industry’s urgent need for lightweighting and low-carbon production has created a strong demand for ultra-large integrated die casting processes, however, meeting this demand is highly challenging.

In addition, faced with whole workshop’s stringent requirement for equipment reliability, YIZUMI tackles challenges with a system-thinking approach, achieving breakthroughs across materials, intelligent control, supply chain, and modular design. This has elevated the 10,000T die casting machine from a “cutting-edge technology” to an “industrial powerhouse” that steadily creates value in customer’s workshop.

In this process, LEAP10000 is beyond a single product. It is also a “symbol of confidence” in YIZUMI’s ability to lead the high-end segment. LEAP10000 successfully overcomes a series of industrial difficulties such as high-pressure, high-flow precision control; large structural component manufacturing; and long-term operational stability. The breakthrough of systematic capability has enabled YIZUMI to transform from a “candidate supplier” of high-end equipment into a “strategic partner,” laying a solid foundation for YIZUMI to enter high-value segments such as battery trays and integrated chassis components.

High-Quality Manufacturing Processes

To offer a wide range of casting products and assemblies, CASTEON employs various manufacturing techniques, including:

• Investment casting
• Sand casting
• High-pressure die casting
• Low-pressure die casting
• Gravity casting
• Forging
• Machining
• Assembly production

Quality and Certifications

Highest quality standards are a core element of Doerrenberg’s corporate strategy. This is underscored by numerous certifications, including:

• DIN EN ISO 9001:2015 (Quality Management)
• DIN EN ISO 3834-2 (Welding Quality Assurance)
• IATF 16949:2016 (Automotive Industry Standards)
• DIN EN ISO 50001:2018 (Energy Management)
• DIN EN ISO 14001:2015 (Environmental Management)

These quality and environmental standards ensure that all processes meet the highest international requirements.

Conclusion

By combining traditional casting expertise, cutting-edge technology, and a well-structured service concept, Doerrenberg Edelstahl GmbH delivers innovative and tailored solutions for a wide range of industries. The company's continuous development and commitment to quality make it a reliable partner for highly precise casting products.

1 - BEV/electronics supply chain dependencies push EU value share down

Most components for ICE vehicles assembled in Europe continue to be sourced locally. Around 85% of parts are produced within the EU, with 76% of their total value created inside the region. For BEVs, domestic sourcing remains comparable at 83%, but the share of value created in Europe is lower, averaging at 70% (not including batteries), as the wider value chain still relies on input from other regions.

Across component groups, EU value creation is highest for chassis, exterior and body, and interior systems. As production moves closer to the powertrain, the regional value share declines, falling to around 50% for electrical and electronic systems in both ICE and BEV vehicles. 

With the Commission’s Automotive Package due 10 December, it is essential that it includes robust measures including local content requirements to help retain value in Europe. Inaction risks deeper job losses and further erosion of industrial strength. Benjamin Krieger - CLEPA's Secretary General

2 - Europe faces a 15-35% cost disadvantage in key components

Europe’s cost competitiveness has continuously weakened across the automotive sector. Rising material, energy, and labour costs, combined with persistent inflation and burdensome regulations, have weighed heavily on productivity. Analysis across 36 automotive components groups shows a cost disadvantage of between 15-35% compared to best-cost regions in Asia and nearby production hubs. Moreover, Europe faces an uneven playing field, competing against regions where the entire supply chain benefits from substantial public subsidies, lower carbon costs, and less stringent environmental rules.

3 - 350,000 jobs at risk by 2030 amid mounting challenges

If current trends continue, European value creation in car parts could be reduced by up to 23% by 2030. This decline reflects both lower production volumes and reduced value per component as the powertrain mix shifts and value moves abroad. The impact on employment is significant: up to 350,000 jobs could be at risk by 2030.

For internal combustion and hybrid vehicles, loss of value is concentrated in electronics, interiors, and body systems, while for BEVs, the powertrain domain also emerges as a major source of risk.

“Europe’s industrial base is under pressure as electrification and global competition shift value to Asia. In a less favorable business environment, strategic policies are vital to retain investment, talent, and high-value segment.” Archibald Poty - CLEPA’s Trade & Market Affairs Manager

Wax or PMMA?

TITAL relies on both lost wax casting and 3D printing of PMMA for the production of investment castings. In the lost wax process, the required wax patterns are traditionally produced by injecting wax into aluminum molds. The wax pattern is then fitted with a sprue system. The feeder and riser are glued on accordingly and the entire pattern is covered with a ceramic shell. After the ceramic shell is in place, the wax is melted out. What remains is a hollow ceramic mold into which the molten metal is poured. The process is similar when using PMMA 3D printed patterns, but with a key difference: instead of aluminum tools for the wax patterns, only 3D data is required. Another advantage is that the sprue system can be printed directly. "In addition, making the wax tools takes a certain amount of time, they are not very changeable and flexible but very cost-intensive," explains Rainer Sabisch. PMMA is a transparent thermoplastic material obtained by polymerizing the monomer methyl methacrylate. Due to its transparency and scratch resistance, PMMA is often used as a lightweight and shatterproof alternative to glass and is referred to as acrylic or Plexiglas. In 3D printing, it is processed as a powder and bonded layer by layer (layer thickness 150 µm) with a special binder to form three-dimensional objects. Voxeljets VX1000 is used for this. A large-format 3D printer with a build volume of 1,000 x 600 x 500 millimeters.

The question is: "When do I choose which process?" Florian Rauscher, Manager On-Demand Printing at voxeljet AG, explains: "The decisive factor is the number of parts needed. In series production, when the quantities become large, wax injection molds are unrivaled and still the first choice. PMMA systems are at their limit here, depending on the complexity of the geometry. Especially for simpler geometries, the tooling costs are manageable and therefore the break-even is relatively low compared to 3D printing. Also, in terms of part cost." A wax pattern molded over a tool costs less than a PMMA model. However, the production of those necessary tools is very expensive initially. TITAL has the corresponding production equipment in-house. The investment casting specialist can operate them in multiple shifts. The production of wax patterns is much faster, provided the tooling is already in stock. Additionally, higher capacities are possible via the wax injection molds set up in a series compared to PMMA 3D printing. The size of parts is not a factor in either process. "It is not a limiting parameter. TITAL can cast dimensions of up to 1.1 x 1.1 meters via both wax and PMMA, though not in one piece," says Rainer Sabisch.

Finally, consistency of is another factor. "If it is known that a motorsport company changes their design every two days, the manufacturers won’t be able to keep up with the constant tool changes," Sabisch says. In the aerospace sector, this applies to research and development. If a part goes through many iterations, especially in the initial phase, the use of PMMA patterns is more efficient and goal-oriented. "At least until the basis for series production is reached," adds Florian Rauscher. Thus, PMMA models are excellently suited for development purposes and small to medium series production.

First contact with 3D printing

TITAL first encountered 3D printing over 20 years ago. It all started with a toolmaker who, even then, was very active in 3D printing at that time. Back then, they were working with polystyrene. "Polystyrene powder in combination with the laser-sintering process was the first process on the market that we could use to generate parts for our purposes," Sabisch continues.

In 2005, voxeljet came along with its new PMMA material set. Ever since, TITAL has been purchasing PMMA patterns from voxeljet, who produces them using the binder jetting process. "The quality is good, the surface is good, the parameters are good," says Sabisch with satisfaction. PMMA has become increasingly popular and has gradually replaced polystyrene completely. The focus was on dimensional accuracy, less on material properties. It turned out that the dimensional accuracy of polystyrene was nowhere near as good as that of PMMA patterns. Laser sintering is a hot process in which the polystyrene material is melted by a laser. The energy and heat introduced by this process often causes distortion in the patterns. Instead, PMMA models are manufactured at room temperature, which is why no warping occurs and high dimensional accuracy is achieved. Another plus point is the negative coefficient of expansion of PMMA. Instead of expanding, PMMA simply collapses when it encounters heat, like when the model is burned out of the ceramic shell. When the ceramic is enrobed and fired, it is less likely that the shell will break.

DMLS (Direct Metal Laser Sintering): An alternative to 3D printing investment casting patterns?

In the past, TITAL's corporate parent, then named Arconic, operated some 3D printing manufacturing facilities in both development and production using metal 3D printing. However, the company distanced itself from purely metallic 3D printing during a restructuring phase over the past decade and has focused on investment casting. "I think metal 3D printing is good and exciting as such. It experienced a certain amount of hype and was an 'enabler' for us, opening doors to new technologies," says Rainer Sabisch. "However, some things did not materialize as we had hoped. The breakthrough failed to materialize. It turned out that metal 3D printing couldn't map everything after all, and it had a much harder time with safety-related aspects, including certification."

One of the main reasons for investment casting is the part size. With metal 3D printing, large-format, topology-optimized structures can hardly be produced. At least not in one piece. Most metal 3D printers offer build volumes averaging 300 x 400 x 400 millimeters. "With PMMA 3D printing, segmentation and subsequent assembly into a single part is possible," explains Florian Rauscher. "This way, customers can produce parts of up to 1.5 meters in size."

In metal printing, there is also the problem of anisotropy. The mechanical properties are not the same in every axis. With investment casting, on the other hand, the mechanical properties are always identical, regardless of the axis. This is not the case with a printed part, so that these are not yet approved for safety-relevant applications, or must be thoroughly checked.

The investment casting process has always been well established and qualified at TITAL. "We can produce safety-relevant, structurally highly stressed parts based on PMMA-printed patterns in the best quality, especially for the sensitive aerospace sector. That does not work with metal-printed parts," says Sabisch.

All around satisfied

Rainer Sabisch is very pleased with the collaboration with voxeljet: "voxeljet delivers high-precision PMMA patterns, even for very complex parts. They enable easy processability in the investment casting process and great design freedom for complex geometries." The resource-saving process can be easily integrated into existing production chains. Through 3D printing-supported investment casting production, TITAL simplifies workflows and benefits from reduced downtimes, which in turn has a positive effect on the casting price.

About TITAL

TITAL GmbH manufactures and develops highly complex, ready-to-install aluminum and titanium investment castings for well-known companies in aerospace, defense, electronics, optics, racing, mechanical engineering and medical technology. More than 90 percent of TITAL's customers are in the aerospace industry, including world leading aircraft manufacturers such as Airbus and Boeing as well as engine manufacturers such as Safran Aircraft Engines. The medium-sized investment casting specialist, which has been part of Howmet Aerospace (then Alcoa) since April 2015, was founded back in 1974 and benefits from over 45 years of experience in investment casting, topology optimization, design-to-cost and rapid prototyping. The Bestwig site in the Sauerland region of North Rhine-Westphalia currently employs around 600 people. The globally active parent company has locations in 20 countries with 65 plant branches and approximately 21,400 employees. In 2022, Howmet Aerospace achieved global sales of around 5.7 billion US dollars.

Investment Casting

Investment casting can be used to produce high-precision and filigree castings. Among the various casting processes, investment casting stands out as complex and labor-intensive. Instead of molding a negative from a solid model, the desired part is modeled from wax or plastic (e.g. PMMA) as a positive. The model is then coated with several layers of ceramic to produce a mold. When the ceramic is fired, the model melts and a hollow ceramic mold remains. The molten metal is then poured into this mold. Depending on the part, the multiple encapsulation process can take several days to weeks. After the melt has solidified, the mold is destroyed and the cast component is reworked or refined for final use. Virtually all castable alloys can be used for the investment casting process.

About TITAL / Howmet

As part of the American company Howmet Aerospace with many years of leading brand recognition in the aerospace components manufacturing sector and approx. 21,400 employees worldwide, TITAL GmbH, headquartered in Bestwig/Westphalia, near Arnsberg in North Rhine-Westphalia, is a manufacturer of globally sophisticated aluminum and titanium investment castings for leading aerospace companies.

About voxeljet

voxeljet is a leading provider of high-speed, large-format 3D printers and on-demand parts services to industrial and commercial customers. The Company’s 3D printers employ a powder binding, additive manufacturing technology to produce parts using various material sets, which consist of particulate materials and proprietary chemical binding agents. The Company provides its 3D printers and on-demand parts services to industrial and commercial customers serving the automotive, aerospace, film and entertainment, art and architecture, engineering, and consumer product end markets.

For more information, visit our website www.voxeljet.com

The commitment is having impact – but how is it perceived in the industry?

Quarzwerke actively communicates its sustainability strategy and substantial investments in renewable energies – through customer dialogue, social media, corporate channels, and press relations. The goal is to offer customers worldwide raw materials with a lower CO₂ footprint, thereby contributing to the sustainable transformation of industry. As a company positioned at the beginning of the value chain, Quarzwerke sees itself as bearing particular responsibility – and this is regularly recognized: among others, with the EcoVadis Gold Rating 2025, the Solar Prize 2022, and the Sustainability Award of the MIRO Industry Association 2024.

The CO₂ footprint has already been verified at plant level – including Scope 3 emissions. Initial product-related figures are available, currently undergoing legal review, and will soon be officially published.

Customers, particularly from the foundry industry, are responding positively to these sustainability initiatives. Nevertheless, cost reduction currently remains the main focus in many cases, while the use of certified low-CO₂ raw materials is increasing more slowly. The same applies to sand regeneration, which is primarily used when it offers clear economic advantages for the foundry.

With its so-called “green sand,” however, Quarzwerke is pursuing a clear future strategy: the company aims not only to strengthen existing customer relationships but also to prepare for new markets. Flexibility is crucial – as Quarzwerke wants to be able to supply CO₂-reduced products as soon as market demand arises. Or, as the company puts it: “We want to provide our customers with tomorrow’s product today.”

To further accelerate the expansion of renewable energy in Germany, Quarzwerke identifies bureaucratic and infrastructural obstacles as key bottlenecks. Overburdened grid operators, lengthy approval procedures, and insufficiently developed power grids delay many projects. In addition, extensive environmental assessments, particularly in species protection, and the limited building privileges for photovoltaic systems in rural areas pose further challenges.

A particular hindrance concerns floating PV systems: the current 15% coverage rule and 40-meter shoreline distance under the Water Resources Act (WHG) significantly restrict expansion potential – even though scientific studies, partly conducted in cooperation with the NRW Ministry of the Environment, show that such systems have no negative impact on water quality, flora, or fauna. Especially on extraction lakes, of which Quarzwerke has many, floating PV systems could therefore represent a space-saving and forward-looking solution for the energy transition.

About Quarzwerke Group

The Quarzwerke Group is an independent family company with 140 years of experience in the extraction, processing and refining of industrial minerals. Our product portfolio includes not only the raw materials quartz, kaolin or feldspar but also the product development. Our main locations are in Germany and Central Europe. As a reliable partner of our customers, we want to achieve long-term value with responsible and motivated employees and in the perception of our social and ecological responsibility.

RFNBO-certified hydrogen available to all types of customers

The Schwäbisch Gmünd site obtained its RFNBO (Renewable Fuel of Non-Biological Origin) certification in September 2025. RFNBO is the European Union’s most stringent standard for renewable hydrogen under the European Renewable Energy Directive. It certifies that Lhyfe’s hydrogen production at its Schwäbisch Gmünd site is 100% renewable and complies with the environmental and traceability criteria that must be met by sustainable activities under the EU Taxonomy.

The RFNBO certificate provides Lhyfe’s customers with proof of the sustainability of the molecule purchased, thus enabling them to be eligible for national and European grant schemes.

Already five years of operations in Germany thanks to some of the most advanced logistics in Europe

Present in Germany since 2020 through its German entity, Lhyfe has already built and operated a first unit in Baden-Württemberg on behalf of Deutsche Bahn as part of its “H2goesRail” project.

The company made its first deliveries of renewable hydrogen in Germany in 2023 to support the development of the first ustakes, thanks to a strong network of customers and partners and a well-established logistics chain. Since 2021, with the gradual commissioning of three sites, Lhyfe has built up a high level of logistics expertise capable of optimising a rapidly growing container fleet. In 2024, the company made more than 470 deliveries in Europe, with a service rate of 99%.

Today, with its 70 high-performance tube trailers ranging from 380 to 1000 kg in capacity, Lhyfe manages one of the largest and most modern H2 containers fleets in Europe.

With the commissioning of this fourth unit in Schwäbisch Gmünd, Lhyfe is strengthening its regional network and will continue to play an active role in the development of the renewable hydrogen sector in Germany by supplying the many players in the mobility and industrial sectors who, without needing an on-site unit, require regular and intensive supplies.

FP: JOEST is considered a technology leader. What are your unique technical selling points?

Dr. Marcus Wirtz: Many of the machines commonly used today were originally developed at JOEST. Our claim is to be a technology leader. We offer individual machines and complete solutions – from 3D planning and recording to customized systems with automation and service.

Our core competence remains vibration technology, but we have expanded specifically through acquisitions – for example, with Dieterle's lifting and tipping technology or Dr. Gössling's magnetic and hinged belt conveyors, which are now part of the JOEST group. This enables us to implement complete furnace charging systems and charging equipment, for example, and to provide parts tracking with RFD chips, automation, and safety solutions.

FP: How much do digitalization and artificial intelligence influence your work?

Dr. Marcus Wirtz: Very strongly. We develop our drive technology ourselves and are increasingly equipping it with intelligence – for predictive and preventive maintenance. AI is becoming a tool for converting the wealth of measurement data into customer benefits and, for example, supplementing the experience of our technicians and engineers. The knowledge remains within the company, but digital systems make it even faster and more precise to use.

FP: How do you deal with global challenges – transformation, geopolitical tensions, new markets?

Dr. Marcus Wirtz: We focus on pooling expertise and are clearly committed to Germany as a business location. During the coronavirus pandemic, we invested heavily in our main site in Dülmen, for example in a stainless steel production facility that is probably unique in Europe. Today, we produce almost CO₂-neutrally – thanks to photovoltaics and geothermal energy.

Our philosophy: Everything related to quality remains in our own hands. At the same time, we are establishing competence centers around the world – in the US, Asia, India, and South America – in order to remain close to our customers. India is a growing and highly interesting market, where we have our own subsidiary that successfully produces for the local market – especially for foundries. The quality requirements differ, but the market is developing dynamically. India will certainly play an important role in the coming years.

FP: What are the biggest challenges and opportunities for the future – and what is your vision for JOEST?

Dr. Marcus Wirtz: Our world will be much more dynamic and unpredictable in the next 10 to 20 years. That is a challenge – but also an opportunity. We have a strong, cross-generational management team and are excellently positioned both technologically and digitally.

Our vision: JOEST will remain a machine manufacturer but will become even more intelligent. We are integrating more digital solutions, automation, and software into our systems and individual machines – while remaining flexible and customer-oriented in all markets.

FP: How are US trade policy and punitive tariffs affecting your business?

Dr. Marcus Wirtz: As a German-American entrepreneur, I know both sides well. Of course, we are feeling the impact of the tariffs – but we are flexible. A complete relocation of production would be risky, as we manufacture over 180 product types, most of which are customer-specific. Quality and technical safety are paramount.

Free trade in the traditional sense is unlikely to return. The US is focusing permanently on national priorities.

FP: You have spoken very clearly about the economic and social situation. What would you like to see from German industry?

Dr. Marcus Wirtz: More courage and less self-criticism. We are world leaders in many technologies – mechanical engineering, foundry, recycling, mining – but we need to communicate this more confidently to the outside world. Germany needs speed, innovative spirit, and the will and courage to implement things again. If we rest on our laurels, we will lose. Entrepreneurship means risk – and responsibility.

FP: Dr. Marcus Wirtz, thank you very much for your clear view of things, your global vision, and your commitment to Germany as a business location. With digitalization, sustainable production, and self-confident mechanical engineering, the JOEST group will continue to set international standards in the future.

About the JOEST group:

With 12 subsidiaries on four continents under the management of Alexander Moormann and Dr. Marcus Wirtz, the JOEST group has a global network and is close to its customers. Since 2001, its international presence has been systematically expanded – from Australia to North and South America to Asia and Africa. With GOESSLING (since 2019) and MOGENSEN (since 2024), the portfolio has been expanded to include specialized solutions in conveying and screening technology. JOEST has always played a leading role in foundry technology worldwide with many new developments and has evolved from a supplier of individual machines to a provider of complete solutions.

Foundry-Planet Interview with Dr. Marcus Wirtz, Managing Partner of the JOEST group

Conducted by Thomas Fritsch, Editor-in-Chief Foundry-Planet GmbH

Tradition Meets Future

The foundry industry – long a cornerstone of industrial value creation – once again proved in Rezzato that it is far more than a relic of the past. Its ability to innovate, adapt, and create genuine value makes it a key player in shaping Europe’s industrial future.
Those who invest in transformation and embrace change today, according to the prevailing sentiment of the convention, will be the ones leading tomorrow.

Following the trade fair, targeted customer visits confirmed the impressions gained, especially with regard to gigacasting. It was noticeable that water-free and water-based spray applications in China are increasingly characterized by extremely low spray quantities and times, a high degree of automation, and special requirements for post-processing. This is leading to increasing confidence in the handling of release agents and large castings. A routine that is still only found in isolated cases in Europe.

It remains to be seen whether and to what extent these developments will also be implemented or pursued in Europe and how the capacity utilization of the large machines is developing in view of the large number of Chinese suppliers.

Trennex's experience at CHINA DIECASTING 2025 underscores how important it is to regularly orient oneself in new and dynamic markets in order to further develop products and services in a targeted manner and tailor them optimally to customer requirements. The company considers itself well positioned to do so: with more than 60 years of experience in the manufacture and development of release agents, close partnerships in the Chinese market, and the ability to adapt solutions to specific requirements, Trennex will remain a reliable partner to the die casting industry in the future.

Adjusting the Product Portfolio – Focusing on Market Share

The motto “Think Tech Forward” perfectly describes YIZUMI’s approach: tackling technical challenges head-on and setting new standards through innovation. To achieve this, the company has realigned its product strategy with a focus on research, efficiency, quality control, and core technologies. Through lean production management, preventive quality processes, and increased investment in R&D, YIZUMI has successfully expanded its competitive edge.

Thanks to a wide range of applications and close cooperation with globally renowned companies, YIZUMI has developed deep expertise in metal casting. In particular, in the field of intelligent high-end equipment for light metal casting, the company works with technology leaders in Europe and beyond to drive innovation and industry growth.

The dynamics of the market are especially evident in the rise of electric vehicles and the growing importance of integrated die-casting technology. As parts become larger and processes more complex, the demands on die-casting machines increase. YIZUMI meets these needs with flexible solutions – from the three-platen machines of the LEAP and HⅡ series to the compact, efficient two-platen machines of the NEXT² series, which are increasingly becoming the preferred choice for large castings.

Global Strategy – Keeping Pace with Industry Trends

The transformation of the automotive industry toward energy-efficient vehicles is driving global demand. While China, the U.S., and Europe lead the way, markets such as India, Indonesia, and Thailand show strong growth potential.

In this context, Chinese companies are evolving from pure exporters into true global players. YIZUMI is actively shaping this transformation by building international teams and strengthening the role of foreign experts in key areas such as R&D, management, and service. Today, the company is present with production facilities, R&D centers, and subsidiaries in China, India, Germany, North America, Mexico, Vietnam, Thailand, Turkey, and other regions.

YIZUMI sees itself as a partner to the global manufacturing industry: with customized solutions for overseas markets, a consistent focus on Industry 4.0 technologies, and a commitment to supporting customers on their path toward electromobility, the company is helping to shape the future of the foundry industry worldwide.

Pressure rise delay with traditional casting units

The conventional cold chamber diecasting process is an established method of producing high-quality cast parts from light alloys, especially particularly rigid, thin-walled components. A key aspect is quick and reliable pressure build-up during the transition from the filling to the compression phase. "Traditional casting units have proven themselves but they have their limits in terms of physics and design, especially due delays caused by a spring-actuated check valve and with respect to the pressure build-up speed. The K-series casting unit from FRECH eradicates these flaws and facilitates significant improvements in the diecasting process and in the quality of the cast parts produced in industrial applications, such as in the mobility sector", explains Peter Maurer, Head of Development, Machine Software at Oskar Frech GmbH + Co. KG. The advanced design and a re-engineered control system simplify process parametrizing thanks to self optimization at start of production. This reduces the pressure rise time to as low as 15 milliseconds, improves the cast part quality and increases reproducibility.

To illustrate the advantages of the FRECH casting unit, it is first worth taking a look at the conventional cold chamber diecasting process. In this process, a hydraulically driven plunger presses the liquid metal alloy into the die at high speed.

"The key factor is that the compression phase (third phase) follows the filling phase (second phase) without delay in order to increase the specific casting pressure promptly while the component is solidifying. This pressure increase triggers an additional intensifier plunger in the casting unit that is set in motion while the filling phase is still underway", explains Dr. Marcel Becker, Head of Technology Management.

In conventional casting units, pressure rise takes 30 to 50 milliseconds, measured from completion of die filling to when around 90% of the compression level has been achieved. With a filling time of 30 milliseconds, the pressure build-up time is roughly the same or even longer – and is thus comparatively high. It is made up of an idle time and the actual pressure rise time. The idle time occurs because, in conventional casting units, the central, spring-actuated check valve has to fully close before the intensifier plunger can increase the pressure. During this idle time of approximately 15 to 25 milliseconds – even longer than 40 milliseconds in the case of large machines – pressure in the die is not increased.

"There is thus a risk that the melt will already partly solidify in the die before compression begins. This in turn can lead to internal material defects within the component, such as shrinkage cavities. In the thin-walled gate area in particular, the melt may solidify during the idle time, depending on the design of the die", says Dr. Marcel Becker, who boasts many years of practice-based experience in diecasting. In cases such as this, the delayed hydraulic pressure increase has no effect, as further compression does not take place, as illustrated in the diagram in Figure 1.

In addition, the central check valve that is subject to a high load represents a further risk: If the spring in a conventional casting unit breaks, the piston, cylinders and valves may be seriously damaged.

Processing of giga and megacastings

Wenzler is well positioned with regard to giga and megacasting projects.

The company is integrated with a leading European partner along the value chain with the WH 10000 machine, underscoring its role as a specialist for structural parts and side members. Wenzler's machine concepts are designed to meet the special requirements of large aluminum cast components – from flexible logistics and parallel machining units to thermally neutral construction. The decisive factor here is availability, which is worth its weight in gold: machines must run reliably 24/7, even under harsh production conditions.

During an informative tour with the management shortly before the delivery of the large machines, we had the opportunity to see for ourselves the technical skills and the logical requirements and solutions.

Big Casting Machine WH 10000 – Parallel machining from two sides

The WH 10000 is a horizontal 5-axis machining center for large aluminum casting machining. Based on HELLER standard components and Wenzler kinematics, the WH 10000 is the ideal machining center for extremely large die-cast aluminum structural parts.

The design of the WH 10000 offers decisive advantages for the machining process of large aluminum structural components. Two linear 3-axis units face each other on a machine bed. The centered workpiece is located on a horizontal swivel axis (A-axis) and can be machined from both sides simultaneously in double spindle operation in a single clamping. Each linear unit is equipped with a 5-axis milling head with two NC rotary axes per head.

OTHER FOUNDRY WASTES AND RECOVERY POTENTIAL

Beyond sand waste, foundries generate by products from melting, shot blasting, and fettling operations. These streams can hold untapped value and call for smarter management:

• Dust collector fines from electric melting can often be repurposed. For example, fumes from galvanised steel scrap contain zinc oxide, which can be extracted and sold for industrial use.

• Silica rich dusts may have beneficial re-use potential in the glass & ceramics industries.

• To preserve reuse potential, it’s essential to segregate dust containing heavy metals, preventing contamination of other waste.

• Small foundries may benefit from clustering together to create viable pathways for reusing baghouse dust from melting shops.

• Aluminium dross can be sent for metal recovery, though economies of scale again favour collaborative efforts.

• Using the John Winter range of fluxes helps reduce aluminium carryover into dross, minimising melting losses.

• Some slag by products are suitable for construction applications, but segregation is crucial – furnace waste with heavy metals must be kept separate.

• Collaborate with customers to phase out heavy metal alloys (e.g. leaded gun metals). In the US, bismuth is now preferred in copper based alloys, virtually eliminating lead use.

MATERIAL CHOICES TO ENABLE REUSE

To promote waste reuse and reduce environmental hazards, foundries should explore:

• Non-crystalline silica refractories, which simplify safe disposal and repurposing.

• Ceramic sands, which reduce crystalline silica content in shot blast and fettling dusts.

• Good housekeeping practices to minimise chemical waste and waste oils, ideally working with suppliers for recycling or takeback schemes.

• Transitioning to non-hazardous materials throughout the process wherever possible.

• Regular audits of all waste streams to uncover potential reuse or safe treatment options.

AIRBORNE EMISSIONS AND SUSTAINABLE ALTERNATIVES

Foundries in Europe face increasing pressure to control volatile organic compound (VOC) emissions and airborne pollutants like formaldehyde. Some sites have installed afterburner systems, but these carry high carbon footprints.

MORE SUSTAINABLE ALTERNATIVES ARE EMERGING

• Inorganic binders are now widely adopted in the aluminium sector and are being trialled in ferrous casting applications to reduce emissions.

• Products like JW’s Winterbond and Geopol inorganic no-bake systems contain zero VOCs and yield non hazardous waste sands, ideal for beneficial reuse.

• JW’s Zero-VOC greensand release agents, including:

0  PF880 (hydrocarbon based)

0 PF990 (vegetable based), which significantly lowers carbon footprint.

By implementing these materials, foundries can virtually eliminate airborne emissions and odours.

CONCLUSION – MANAGING FOUNDRY SAND WASTE

• Increase beneficial reuse opportunities.

• Invest in advanced reclamation technologies.

• Adopt non hazardous processes to enable safe reuse.

• Continuously audit and optimise sand waste handling.

CONCLUSION – HANDLING METALLURGICAL AND PROCESS WASTE

• Segregate waste with heavy metals to avoid cross contamination.

• Collaborate with customers to remove hazardous alloy elements.

• Use low silica refractories to reduce airborne hazards.

• Recover and reuse aluminium dross and slag.

• Cut melting losses with proper fluxing.

• Minimise chemical waste – work with suppliers on takeback schemes.

STRATEGIC TAKEAWAY

Above all, foundries should prioritise non hazardous production, waste stream optimisation, and collaborative approaches like clustering sustainable practices economically viable.

Technical highlights of the WH 10000

• High agility

• 5-axis machining

• Two spindles in use

• Large travel range

• Fast automatic tool change

• Minimum quantity lubrication (MQL)

• Unobstructed view for the operator

• Central chip disposal

• Automatic loading and unloading by robot/gantry

Details here: 

https://august-wenzler.de/de/wh10000.html

https://www.heller.biz/de/maschinen-und-loesungen/big-casting-bearbeitungszentrum-wh-10000

Appeal to European car manufacturers

Wenzler believes that European industry needs to stick together more closely in the face of international competition. Instead of competing for margins and individual orders, more openness and cooperation is needed – especially with regard to China, where projects are implemented uncompromisingly and free from economic constraints. “We are all in the same boat. If the OEMs falter, it affects the entire supply chain,” is the urgent appeal.

Wenzler thus positions itself as a highly specialized solution provider that focuses not on size, but on process expertise, close customer integration, and sustainable availability. The Spaichingen-based company is convinced that the key to competitiveness lies in the interaction of the entire value chain – from casting to final machining.

About August Wenzler Maschinenbau GmbH:

Wenzler is a mechanical engineering company based in Spaichingen, Germany, founded in 1954. The company develops and manufactures machining centers and production solutions that are used in particular in the machining of light metal and structural components for the automotive and supplier industry.

Since 2012, Wenzler has been majority-owned by the HELLER Group, a leading international manufacturer of machine tools. This affiliation allows Wenzler to combine its specialization and experience with HELLER's global presence and system expertise, benefiting from its worldwide sales and service network. This strengthens Wenzler's market position and enables access to new markets.

About Merrin Muxlow:

Merrin is a marketing and research leader with deep expertise in the industrial sector, particularly casting and advanced manufacturing. She heads partnerships for the Investment Casting Institute and serves on the boards of the Investment Casting Foundation and the METAL for America Advisory Council. As both a strategist and author, she brings perspective on the full industrial landscape—from workforce development and supply chain resilience to technology adoption in foundries. 

About Timothy Sullivan

Tim brings more than 30 years of leadership experience in the investment casting industry, most recently serving as Vice President of Corporate Affairs and Services at Hitchiner Manufacturing. Beyond his industrial leadership, Tim has held trustee roles with the Aircraft Builders Council and several healthcare organizations in New Hampshire, underscoring his commitment to both industry advancement and community impact. Tim’s deep expertise, strong industry relationships, and strategic vision make him well-positioned to lead ICI into its next chapter.

Source: www.investmentcasting.org

Successful Series Integration at BMW

A standout reference project is the collaboration with BMW, where RS's automated wall thickness measurement has been successfully integrated into the series production of rear axle carriers. This example demonstrates that even complex aluminum components with varying wall thicknesses can be reliably inspected inline – without compromising cycle time or accuracy.

Reliable dialogue between business and politics

The discussion with Minister Neubaur was characterised by an open exchange,’ explain Dirk Howe and Dr. Georg Geier, both managing directors of Siempelkamp Giesserei. ‘We were able to outline the specific challenges facing energy-intensive SMEs – as well as the investments we are making to meet them. We consider it an important signal that our solution for successful transformation and our clear commitment to Germany as a business location have met with genuine interest and attention.

The measures are part of a long-term transformation process. The aim is to harmonise technological development, location loyalty and social responsibility with collectively agreed jobs and practical training, thereby making a solid contribution to industrial production in Germany.

Investment priorities: digitalisation, energy, sustainability

The investment program, which is currently being finalized, focuses on three key areas: the expansion of digital production and control processes, the transition to CO₂-reduced and ultimately CO₂-neutral manufacturing, and the creation of a stable, flexible energy infrastructure to secure valuable industrial jobs.

We would like to express our special thanks to Minister Neubaur for her visit, the pragmatic exchange on pressing issues and the support she has promised,’ Howe concluded. ‘Especially in challenging times, dialogue between industry and politics is crucial for a common understanding of reliable prospects and viable solutions in the interests of a strong, future-oriented German industry.

Economics Minister Mona Neubaur emphasised: "Foundries in North Rhine-Westphalia are indispensable for our industrial location – especially for key sectors such as mechanical engineering and vehicle manufacturing. Without them, there would be no wind turbines, no electric motors, no precision parts. As a state, we are creating the framework conditions for a successful transformation with attractive investment programs and funding opportunities. We want to strengthen North Rhine-Westphalia as an industrial location, secure sustainable growth and preserve jobs. The good news is that many foundries in North Rhine-Westphalia are investing courageously in climate-friendly technologies, renewable energies, digitalisation and new materials. I am impressed by the commitment with which Siempelkamp Giesserei is driving forward the digital, sustainable and economic transformation."

About Siempelkamp

Siempelkamp Giesserei in Krefeld specialises in the production of large hand-moulded castings weighing up to 320 tonnes made of spheroidal graphite cast iron. With a casting volume of over 60,000 tonnes per year and 400 employees, it is one of the largest hand-moulding foundries in the world. The comprehensive and customer-oriented service package includes the supply of structural components for many innovative machine manufacturers in the energy industry, the raw materials industry, press construction, steel production, automotive and many other areas of transformation.

Siempelkamp is a globally active group of companies with business divisions in machinery and plant engineering, casting technology, engineering and service. Around 3,000 employees worldwide ensure that the Siempelkamp Group is among the world leaders with its technologies.

Sustainability: Racing Toward a Greener Future

Beyond performance, aluminium offers a significant sustainability advantage. Unlike many industrial materials, aluminium is infinitely recyclable, it can be reused repeatedly without losing its structural or mechanical properties. Recycled aluminium requires only about 5% of the energy needed to produce primary aluminium from raw ore, making it an eco-conscious choice for modern engineering.

Formula One, through its long-term sustainability initiatives and its goal to become net carbon zero by 2030, is increasingly turning to circular economy principles. Many teams now incorporate recycled aluminium into their design and manufacturing processes, reducing carbon footprints without compromising competitiveness.

Enabling Innovation and Pushing Boundaries

The versatility of aluminium extends beyond individual parts. It enables innovations in modular manufacturing, rapid prototyping, and lightweight composite integration. Teams are constantly experimenting with new aluminium alloys and hybrid materials to reduce weight, increase stiffness, and boost crash resistance.

This constant innovation cycle in F1 eventually trickles down into mainstream automotive applications, influencing the design of commercial electric vehicles, aircraft, and even sports equipment.

Conclusion

As Formula One continues to evolve at a blistering pace, aluminium remains a foundational material behind the sport’s engineering marvels. It embodies the core values of modern motorsport: performance, efficiency, safety, and sustainability. Whether in the heat of a Grand Prix or during off-season development, aluminium is the quiet force powering the fastest cars on Earth.

For further information about aluminium in Formula One and how it is shaping the future of mobility, follow our social media campaign under #AluminiumInF1.

Source: ALFED - The Voice of the UK Aluminium Industry

A tour of the Fraunhofer IGCV provided insight into current projects 

Prof. Dr.-Ing. Volk has played a key role in shaping the strategic direction of the institute in recent years. From July 2022 to July 2025, he will also take over as managing director of the Fraunhofer IGCV. Together with Prof. Dr.-Ing. Klaus Drechsler and Prof. Dr.-Ing. Rüdiger Daub, he will head an institute that stands for excellent research and industry-oriented development.  

The Fraunhofer IGCV stands for application-oriented research in production. The focus is on transferring basic knowledge into customer-specific solutions. The institute's unique selling point lies in its interdisciplinary approaches, which intelligently combine foundry, composite and processing technology. This mix enables complex challenges to be solved in a practical manner along the entire process chain. Visitors to the summer party were able to see the latest industry-oriented developments during a guided tour of the modern institute building.  

The summer party therefore not only offered an insight into current projects, but also provided a platform for exchange between science, industry and young professionals – a successful example of a living technology transfer culture.

Future-Oriented Solution for the Foundry Industry

With this technology, RS is setting new standards in the quality assurance of cast parts. The solution not only enables early defect detection during the process but also makes a significant contribution to increasing efficiency and reducing scrap and rework.

Especially for components with varying wall thicknesses – increasingly required in modern vehicle structures and mechanical engineering – the automated inspection offers a new dimension of process reliability.

Conclusion:
RS’s automated wall thickness measurement is a groundbreaking step towards the smart foundry – precise, efficient, and ready for industrial transformation.

A shared goal: greener foundry operations

Fritz Winter and KLEIN Anlagenbau are pursuing a joint mission to optimize manufacturing processes while improving sustainability. The new systems:

• minimize dust emissions and support compliance with strict air pollution control regulations,

• reduce waste such as residual dusts,

• and significantly lower overall energy requirements.

This approach enhances both production performance and environmental responsibility.

There will also be a German pavilion this time.

Building on the momentum of the last edition, the 2025 event is already seeing strong exhibitor interest. A German Pavilion will once again be part of the fair, and for the first time, it will feature a new, modern, and sustainable stand construction concept across all four events – wire, Tube, GIFA, and METEC.

With a dynamic exhibition environment and a broad range of international participants, GIFA Southeast Asia 2025 is set to become a key meeting point for the Southeast Asian foundry industry. The organizers have put together an engaging and diverse program to support this goal.

About Thailand:

Thailand is a strategic hub for metals, automotive, electronics and construction, offering access to one of the world’s fastest growing regions in ASEAN. Centrally located, it provides unmatched connectivity for trade and supply chain operations.

With strong government support for Industry 4.0 and smart manufacturing, Thailand is rapidly advancing in automation and digital production. Continued foreign investment fuels its growth as a regional base for industrial innovation, exports and distribution across Asia Pacific.

Take advantage of Thailand’s dynamic business landscape and position your brand at the centre of Southeast Asia’s industrial transformation.

Franz-Josef Wöstmann and Dr. Rudo Grimm Seal the Partnership

Following a successful prototype phase, production is planned at Lenord+Bauer’s site in Gladbeck — ideally using components sourced entirely from European manufacturers. "With this partnership, we are creating a forward-looking alternative to the drive solutions that are currently predominantly produced in Asia," explains Dr. Rudo Grimm, Chairman of the Executive Board at Lenord+Bauer.

By combining Lenord+Bauer’s application and manufacturing expertise with Cast Coil’s innovative technology, a powerful, reliable, and sustainable motor will be developed. It is specifically designed for the rapidly growing transport drone sector and other e-mobility applications where maximum reliability and efficiency are essential. “Together, we are setting new standards for European drive solutions,” adds Franz-Josef Wöstmann, Managing Director of Cast Coil GmbH.

The production of the first prototypes is scheduled to begin in the third quarter of 2025. Both companies see this partnership not only as a major business opportunity but also as a significant contribution to Europe’s technological sovereignty in the strategically important field of e-mobility.

Source: Cast Coil Technology • Next generation e-drives!

WFO Jozef Suchy Medal Awarded to Denny Dotson (USA)

A highlight of the AFS Annual Banquet—chaired by Angela Schmeisser and attended by prominent figures from the U.S. industry—was the presentation of the prestigious WFO Jozef Suchy Medal to Mr. Denny Dotson, awarded by Secretary General González.

The Jozef Suchy Medal honors outstanding individuals from WFO member associations who have demonstrated a strong commitment to sharing their knowledge with other WFO members, in memory of Jozef Suchy's extraordinary contributions to the organization.

Denny Dotson has been deeply engaged in the metalcasting industry throughout his career. He served as president of both the American Foundry Society and the Ductile Iron Society and led Dotson Iron Castings until its sale to MacLean Power Systems in 2023. As an active WFO member, he has significantly contributed to global initiatives to promote the U.S. metalcasting industry and played a vital role in advancing the WFO’s mission and development. His instrumental role in founding the WFO Strategy Group laid the groundwork for a new form of international cooperation and created additional value for the industry—most notably, the World Foundry Summit for foundry CEOs.

“This is one of the most emotional recognitions I’ve ever received. It has been an honor to work with the WFO,” Dotson said during the award ceremony.

Successful Event in Atlanta

Both the WFO and AFS expressed their satisfaction with the overall attendance and the outcomes of the events organized in cooperation. They emphasized that the initiative was a tremendous opportunity to strengthen ties between the global foundry industry and its U.S. counterpart.

Doug Kurkul, CEO of the American Foundry Society, praised the collaboration between the two organizations, stating: “We have many great memories from CastExpo and the WFO World Technical Forum.”

"Handtmann has set itself the goal of combining the latest supplier technologies with megacasting. The changed requirements for components and the increased customer demands in terms of quality and safety confirm our strategy," said Heiko Pfeiffer, Co-CEO of the Light Metal Casting Division.

Megacasting is a production process that enables the manufacture of large and complex structural components in a single casting. The main advantages of large cast components for customers include a high level of functional integration, reduced manufacturing complexity and lower procurement and logistics costs. Numerous process steps in production are saved and labor-intensive joining and post-processing steps such as welding and gluing are avoided. In addition, the weight of the car body is significantly reduced, which is particularly relevant for electric vehicles. With megacasting, Handtmann significantly reduces production time in automotive production, significantly improves material efficiency and also increases the structural integrity of vehicles.

The Handtmann Group of Companies decided to invest in the first megacasting die casting machine and invested an amount in the double-digit millions. The process, which is in high demand in the USA and Asia, is still new in Europe. Handtmann is the first European supplier to use megacasting in series production. With this investment, the Group aims to strengthen its German production facilities and cooperation with its European customers and business partners.

Get also Information about: Megacasting has started a new era

The Handtmann Group

The Handtmann Group is a globally active technology company in the processing industry with around 4,700 employees, including 3,300 at its headquarters in Biberach an der Riß, Germany. Cutting-edge technology, innovation, and a people-centered approach are at the heart of this family-owned business. The group is organized into six business divisions with autonomous management structures: Light Metal Casting, Systems Engineering, Filling and Portioning Systems, Plant Engineering, Plastics Technology, and e-solutions. At the top of the corporate structure, a holding company functions as the management, financing, and investment entity.

In 2023, Handtmann generated a turnover of 1.3 billion euros. Through a consistent reinvestment strategy, the company owners enable substantial investments in research and development as well as production facilities. In doing so, the founding family sustainably supports qualitative growth.

The group is currently active in over 100 countries with its own production sites, subsidiaries, and representatives. Founded in 1873 as a brass foundry, the Handtmann Group celebrated its 150th anniversary in 2023.

www.handtmann.de

Light Metal Casting Division

As part of the Handtmann Group, the Light Metal Casting division is a strategic partner for the development and production of aluminum die-cast components for the automotive industry. Handtmann is the first European Tier 1 supplier to produce structural components using the emerging innovation of megacasting.

The subsidiary is the largest family-run light metal foundry in Europe, with sites in Germany, Slovakia, and China.

https://www.handtmann.de/leichtmetallguss

Investments with Substance – New Aluminum Casting Line
The entire brake disc production is to be consolidated at the Breidenbach site.
One example of this new strategic direction is the investment in a new horizontal aluminum casting line, designed to manufacture lightweight brake discs combining grey cast iron, stainless steel, and aluminum. The line is scheduled to go into operation during the first half of the year 2026 and is expected to run in three shifts in the future. The initiative was market-driven and targets major OEMs and their electric platforms. For a traditional iron foundry, this represents a true innovation – and underscores the strategic relevance of this development: lightweight composite brake discs will be produced by casting an aluminum hub onto a grey cast iron friction ring with embedded stainless-steel pins.
In parallel, a comprehensive modernization project for “Foundry 1” is underway in cooperation with GEMCO under the guiding principle “Make the Concept Stronger.” The aim is to automate processes, increase efficiency, reduce CO₂ emissions, and meet economic requirements.

Key Metrics and Focus
Currently, Breyden GmbH produces 13–14 million brake discs annually (capacity: up to 16 million across 15 shifts) – around 60,000 to 65,000 units per day. With the planned consolidation of brake disc production at the Breidenbach site, efficiency is expected to improve further.
Steffen Sasse, Foundry Director since 2018, emphasizes the technological flexibility of the facility. Nevertheless, the clear focus remains on brake discs: “Foundries that try to cover too broad a market struggle during times of overcapacity.”

Digitization with a Sense of Proportion
Rather than engaging in digital activism, the leadership at Breyden GmbH is pursuing targeted digitization with tangible benefits. Process data is collected from existing control systems, analyzed, and used, among other things, for AI-supported scrap analysis. In the melting shop, intelligent material composition also enables more efficient production.

The Future of the Brake Disc
Brake discs remain essential even in electric mobility – in some cases, even larger ones are needed due to increased vehicle weight. Challenges such as corrosion from reduced brake wear or flash rust remain – but also present opportunities for innovation. The lightweight composite brake disc is a direct response to the demand for weight reduction.
The topic of fine dust (keyword: Euro 7 standard) is still ongoing with iDisc II. OEMs are currently focusing on series release, but in the long run, the focus will shift toward cost reduction while maintaining environmental performance. New powders, processes, and close development cooperation with TMD Friction – another company in the AEQUITA portfolio – are driving this advancement.

Germany as a Production Location: Clear Positioning Despite Challenges
AEQUITA and Breyden GmbH are firmly committed to Germany as a production location. However, much depends on political framework conditions such as electricity prices and CO₂ certificates. Mr. Simon warns: “Foundries are part of the industrial backbone – if we lose that know-how, we lose more than just a product.”

Strategic Alignment & Collaboration as Key Success Factors
A defining element of the conversation was the company's collaborative mindset. During the rebranding process, customers reportedly stated that “Breyden is easy to work with.” The goal is to become involved even earlier in the development processes of OEMs.
Breyden GmbH sees itself not merely as a foundry, but as a technology and development partner, one that also integrates more deeply into the value chain. Nevertheless, the core business of cast blanks remains essential to ensure capacity utilization. Innovation and new business models are intended to build upon that foundation.

Conclusion
Breyden GmbH demonstrates how tradition, technology, and transformation can be successfully integrated. Under the umbrella of AEQUITA, the company is evolving into a future-ready, technologically ambitious foundry operation with a clear position in the European brake disc market – and with a strong commitment to innovation, quality, and its domestic production site.

Interview: Foundry-Planet | Interviewees: Sebastian Simon, Steffen Sasse, Jan-Christopher Schwehn

About Breyden – The brake disc company

Founded in 1913, Breyden operates multiple sites in the German state of Hesse, including state-of-the-art foundries, production and machining facilities in Breidenbach and Lollar, as well as our Brake Disc Innovation Center in Ludwigshütte.

• Employees: 560

• Brake discs produced in 2024: approx. 13 million

• Product portfolio:

  • EU7 coated brake discs (iDisc II)

  • Lightweight brake discs

  • Grey cast iron brake discs (ventilated and solid)

Centralized binder handling for the new core shop

In parallel with the conveying systems, the newly constructed core shop at Fritz Winter was equipped with a fully integrated binder unloading, storage, and supply system from KLEIN Anlagenbau. This installation includes:

• a dedicated unloading station for silo trucks,

• two double-walled 30 m³ storage tanks for the binder components,

• and fully enclosed, double-walled supply lines with leak detection to the core production cells.

All system components have been designed with maximum environmental and operational safety in mind—an essential factor given the strict environmental regulations at the site.

With its investment in state-of-the-art pneumatic conveying and binder logistics technology, Fritz Winter strengthens its long-standing collaboration with KLEIN Anlagenbau. The result: improved material handling, reduced operating costs, and a further step toward a cleaner, more sustainable foundry operation.

• Resurgence in Cleaning Room Upgrades
  Delivered full cleaning room upgrades, responding to a growing demand for modernization. 2024 marked a notable resurgence in cleaning room transformation projects.

• Unprecedented Growth in Revenue and Capabilities
  Achieved exceptional growth in revenue, expanded our team, and enhanced our capabilities, solidifying GK’s position as a market leader.

• Launch of a New Website
  Introduced the all-new GK SYSTEMS website in the spring, offering an improved user experience, better access to resources, and a modernized digital presence to serve customers worldwide.

As 2025 begins, General Kinematics is poised to build on its success with renewed optimism and ambitious goals.

International Growth with European Focus

Schüle recognized the need for strategic internationalization early on. In addition to its headquarters in Germany, the company operates plants in Poprad, Slovakia, and Swiebodzice, Poland, with over 550 employees combined. These sites complement rather than replace the German operations.
“Our locations are strong as a network – not in isolation,” says Bruchner.
Unlike many competitors who outsource to Asia, Schüle is firmly committed to European-based production. “Every customer receives one solution: the Schüle solution,” adds Bechtle.

Investments in the Schwäbisch Gmünd site continue. The last major expansion took place in 2012 with the construction of a high-tech production hall. Today, the facility houses not only manufacturing operations but also all central technical and administrative departments as well as Schüle’s in-house tool shop – a core element of its innovation strategy.

The GDK4800next at a Glance

A more detailed overview of the highlights and advantages of the GDK4800next will follow in a separate article. For now, here is a brief outline:

• Highly dynamic casting unit:
  Extremely fast plunger acceleration of up to 650 m/s², pressure build-up times as low as 21 ms, high dynamic casting forces; universally adaptable for all component requirements.
• Reduced footprint:
  Smaller installation area with large opening strokes and minimized opening/closing times.
• Energy efficiency:
  Significantly lower energy consumption and connection power.
• Optimized opening force:
  40% higher opening force over the entire stroke — ideal for three-plate die technology.
• Highest positioning accuracy:
  Precise and flexible programming of opening and closing movements.
• Reduced cooling water consumption:
  Up to 50% less water consumption thanks to innovative drive concepts.
• New hydraulic concept:
  Tank volume reduced by approximately 40%.

CCO Dr.-Ing. Alexander F. Marks, together with his colleagues Jürgen Lamparter and Tobias Just expressed great satisfaction with the success of the event. Especially in economically challenging times, the strong turnout was seen as a very positive sign.

The event focused on the entire die casting process chain. Presentations by:

• Roger Rapp (MELTEC Industrieofenbau GmbH), – Innovative furnace technology and vacuum dosing for large-scale casting
• Norbert Obermair (ROBAMAT Automatisierungstechnik GmbH) – Innovative temperature management systems to cast large structural castings
• Dirk Könsgen (Maschinenbau Böhmer GmbH), – Flexible spraying technology for large castings with the BÖHMER Megabox
• Lisa Aulbach (Aulbach Automation GmbH) – Challenges and trends in the trimming process of large structural die castings parts
• Norbert Feth (FRECH ZPF GmbH) – Innovative temperature management systems to cast large structural castings
• Martin Afkam (VDS SA) – Efficient vacuum process for structure or big casting parts rounded out the program, offering valuable insights into all stages of production.

All in all, a highly successful event marked by excellent organization, valuable information, and an inspiring atmosphere — a strong signal for the future.

Glückauf!

“We produce high-tech products and need a high-tech environment to match,” says Bechtle.

High-Tech Castings for Tomorrow’s Demands

Schüle’s die-cast parts are used in various sectors – automotive, industrial applications, building technology, and soon in medical technology.
In automotive, the company supplies a wide range of components for transmissions, cooling systems, and electronics. Cooling housings and electronic enclosures are growing areas of focus, driven by the industry’s need for lightweight, energy-efficient solutions.

In the industrial sector, Schüle manufactures complex, pressure-tight pneumatic components with extremely fine structures and tight tolerances.
In building technology, Schüle supplies parts for high-efficiency gas heating systems – including heat exchangers with intricate inlay techniques.
From 2025 onward, the company will produce components for the medical sector, including cylinders and heads for dental compressors used in dental practices.
The new Lifestyle unit will serve customers in the recreation and leisure industries.

The Fascination of Die Casting

Die casting is one of the fastest and most cost-effective metal forming methods for medium and large series production. In fractions of a second, molten aluminum is injected into steel molds under pressures of up to 1,200 bar. The metal solidifies instantly and takes the exact shape of the mold cavity – with the mold held closed by forces of up to 4,000 tons.

This process allows for the production of complex, thin-walled, lightweight components with high strength and design flexibility – ideal for today’s lightweight construction needs.
Aluminum die casting makes a crucial contribution to CO₂ reduction across various applications.

Conclusion:
The Schüle Group continues to grow steadily – driven by innovation, technical expertise, and a deep commitment to quality. As new technologies, materials, and industries emerge, Schüle is poised to seize the opportunities ahead.

“We aim for organic growth through our own strength,” summarizes Bruchner. “Our doors are open to new applications, new markets, and new customers. Wherever quality in die casting is in demand – that’s where we belong.”

Find out more 

Advanced Features for Maximum Efficiency

• Optional laser measuring system: Compensates for batch fluctuations for consistent quality.

• Optional Tablet: Enables remote monitoring, teach-in processes, and user-friendly operation.

• Windows-based control: Supports offset programming, comments, unlimited programs, and remote support via TeamViewer.

Our experts Rafael Dineiger and Dennis Gundel will be on-site to demonstrate how these innovations can transform your foundry operations.

• Georgia World Congress Center, Atlanta

• April 12-15 | Booth 2620

• Let’s shape the future of casting finishing together!

Visit Our Website, email us at rdineiger(at)reichmann.com or call +49 172 7053 522 for more details.

Contact

US Headquarter
Reichmann North America LLC
601 S Rancho Dr. Suite C25
Las Vegas, NV 89106
Phone : +1 248-315-9300
info(at)stratecasts.com

or 

More on that soon.

Of course, the social program was another highlight, and Freiberg – with its historic Bergakademie – once again proved itself a perfect host, meeting all expectations.

Factory tour highlights innovation 

Delegates toured the Seojin System’s factory, where they observed the Carat 920 die-casting machine in action.  Bühler engineers are currently installing the second machine, further expanding Seojin’s production capacity with up to 200,000 parts per year per machine for electric vehicles such as battery trays, and rear underbodies. This latest installation builds on the companies’ ongoing collaboration, which began with the Carat 610 project in 2019. The addition of the Carat 920 machines strengthens Seojin’s production capabilities and expands its casting operations. By enabling the production of larger components, megacasting technology improves manufacturing efficiency, reduces material waste, and supports more sustainable production processes. 

Expansion plans don’t stop there. Seojin System is already in the construction phase for another factory which will be completed in 2025. Seojin is planning to also cooperate with domestic partners to provide casting parts for companies in the automotive parts supply chain in Vietnam.  

A groundbreaking technology 

Bühler has been at the forefront of die-casting technology for nearly a century, with its Carat series developed to meet the growing demand for larger structural castings in modern vehicle design. The series features two-platen technology with locking forces ranging from 10,500 to 92,000 kilonewtons, enabling the production of large and complex parts. By replacing up to 100 individual components with a single die-cast structure, megacasting simplifies assembly, reduces welding and joining processes, minimizes material waste, and enhances vehicle performance through lighter and more rigid designs. This approach also lowers logistical complexity and energy consumption, contributing to more sustainable manufacturing.

With manufacturing sites in Europe, the US, and China, Bühler maintains regional production to better serve its customers. Today, more than 900 Carat machines are in operation worldwide, making it one of the most widely adopted solutions in the industry.

Minister President Dr. Markus Söder emphasized: Electromobility made in Bavaria: this is a milestone for MAN and Bavaria as an industrial location! With a state-of-the-art site policy and great cooperation between management, works council, employees and politicians, MAN has successfully transformed itself from a former site for pure diesel engines into a state-of-the-art battery production site for electric trucks. This strengthens the location, secures and creates jobs and international competitiveness. Bavaria is and will remain an automotive state - also in the commercial vehicle sector. Following initial funding of 30 million euros in 2022 for research and development, the Free State is supporting the future production of battery modules with almost six million euros.

The start of battery production is already the second new production line to be opened in Nuremberg this year. The production of the latest generation of MAN diesel engines, which are used in the new D30 PowerLion driveline, is also an investment in the future and secures many jobs at the site. MAN has invested around 250 million euros in this project. MAN currently assumes that almost half of the trucks in Europe and around 90 per cent of city buses will be delivered with zero-emission drive systems by 2030. The highly efficient, fuel-efficient D30 engine will therefore still be needed well into the 2030s. Other engine platforms and series will also be available in MAN's external engine business in the long term. 

MAN eTruck production starts in June 

At the MAN site in Nuremberg, battery packs are manufactured in three so-called form factors. A flat form factor is used in the MAN Lion's City E, the battery-electric city bus. Two other form factors are used in the MAN eTGL, MAN eTGS and MAN eTGX eTrucks with total weights of 12 to 50 tonnes. The start of series production of the MAN eTrucks eTGS and eTGX in Munich is planned for June this year.  

In the current expansion stage, 50,000 battery packs can be produced per year in Nuremberg. However, the new M50 building is designed to be able to produce 100,000 units per year. Battery production will be scaled up depending on the demand for battery-electric vehicles.  

MAN uses NMC cell chemistry (‘nickel-manganese-cobalt’) in its batteries, which has been specially adapted to the operation of commercial vehicles. The battery management system (BMS) continuously monitors the condition of the cells during operation. If, for example, an unforeseen event occurs, it takes internal measures to ensure a safe state of charge. In the event of an accident, the BMS immediately disconnects the battery from the rest of the vehicle (high-voltage emergency shutdown). It also uses an intelligent heating and cooling system to keep the battery cells in an optimum temperature range at all times.  

Modular production is a technological highlight in the large-scale production of battery packs that is now starting. This means that MAN works with a system without a conveyor belt and cycle that can handle different product variants and can be easily adapted to new variants. The decoupled stations can be operated and converted independently of each other, and the battery packs flow through the production system depending on individual requirements and condition. This is made possible by a high degree of digitalisation and automation in the production flow and material provision, which is fully automated with intelligently networked automated guided vehicles (AGVs). This ensures the necessary flexibility and versatility as well as the economical production of different battery packs. 

100 per cent final inspection  

Quality and safety have always been top priorities in MAN production. This also applies to new battery production. Every battery pack undergoes an ‘end of line’ test at the end of production. The focus here is on various software tests, electrical tests such as charging/discharging, checking the data of the battery cells and modules transmitted by the supplier and a leakage test. After all, the compact power storage units have to withstand wind and weather as well as a steam jet. To this end, each battery is subjected to 23 test programmes and around 400 test parameters are recorded. This is documented individually for each battery. This means that the production process can still be traced even after 15 years. 

Listen to presentations from the following companies:

Audi | Automobili Lamborghini | AVL List | DLR Institute of Vehicle Concepts | Ducker Research Europe | Eisenwerk Brühl | Hydro Aluminium Deutschland | FEV Europe | Fraunhofer Institute for Structural Durability and System Reliability LBF | Fritz Winter Eisengießerei | Hydro Aluminium Deutschland | KAMAX Automotive | MAGMA Gießereitechnologie | McLaren Automotive | Nemak | Raffmetal | TiK Technology in Plastics | Volkswagen | Hydrogen and Fuel Cell Initiative Hesse

The redesign of the ATIK METAL foundry plant in Aliaga, Turkey, is one of the largest orders in the 30-year history of VHV Anlagenbau GmbH. As a renowned manufacturer of belt conveyor systems and specialist in steep conveyor technology, VHV was selected to supply customized solutions of the highest quality for this major project.

Cooperation and partnership

When selecting suppliers, owner and managing director Mehmet Atik focused on the highest quality and smooth interfaces. The cooperation with companies such as VHV Anlagenbau GmbH, Eirich official | Maschinenfabrik Gustav Eirich GmbH & Co KG , Heinrich Wagner Sinto Maschinenfabrik GmbH and JOEST group was decisive for the success of the project. Thanks to the long-standing partnership and trusting cooperation, innovative solutions were developed and implemented.

Project scope and implementation

The project comprised the development and implementation of a state-of-the-art foundry system that met the market requirements for ever larger castings. Close coordination and quick decision-making in team meetings led to optimizations in the project process. The involvement of Mehmet Atik in the meetings enabled immediate clarification and the rapid implementation of suggestions for improvement.

Lively panel discussion:
Dr.-Ing. Detlef Kube Klaus A. Bruchner Tobias Gotthardt Max Schumacher and moderator Martin Vogt discussed how to counteract the looming deindustrialisation in Germany. There is a clear set of demands for the new federal government, state governments and European politics.

The pressure die-casting industry expects fair market conditions, a reduction in bureaucracy and planning security in the European consensus.

The pressure die-casting industry in Germany is ready to take on the challenges together and to actively do justice to the importance of the casting industry.

This requires less individual subsidies and more urgent action from the political side. Summary: The signals of departure have been received – let's go!

The program was complemented by a specialized exhibition of the supplier industry and the traditional Foundry Evening, offering ample networking opportunities.

Thanks to Partners and Participants

Fischer concluded by thanking the speakers, partners, and organizers, including Messe Nürnberg, the EUROGUSS team led by Christopher Boss, insightfabrix solutions GmbH, and the BDG team led by Managing Director Max Schumacher. The Die Casting Day remains the most important platform for exchanging ideas on innovations and future perspectives in the industry.

The opening concluded with the handover to Dr. Achim Keidies, who guided the participants through the remainder of the program.

Newform is determined to be the go-to company for innovative insulation and filtration solutions. Following their success with Mica products (see earlier editorial: Asbestos-free Mica slip plane for ferrous and non-ferrous foundries), Team David & David are now expanding their portfolio and looking to establish themselves further in the U.S. market.

You will also have the opportunity to schedule a meeting with them at the Promeos booth, where we are happy to support their journey and help connect them with the right audience.

CastExpo 2025 in Atlanta – Booth at Promeos No. 2825 (with Event for special guests: https://promeos.com/promeos-in-the-usa) 

Meet the German cowboys and discover how Newform is shaping the future of insulation and filtration materials!

Technical details and equipment

The foundry plant has impressive dimensions, with factory halls 350 metres long, 120 metres wide and a 24 metre high compact plant in the central preparation area. The plant is equipped with state-of-the-art technology, including 4 Eirich mixers in the Evactherm® system, the HWS 5 and HWS 6 moulding plants and 4 electric furnaces for melting molten iron.

Another important aspect is the sustainability of the project, as a large proportion of the material melted down is reused from scrapped ships.

With the HWS6, ATIK METAL may not have quite the largest moulding boxes in Turkey (2.38 m² instead of 2.44 m²), but with 80 moulds/h it has achieved four times the cycle rate of others.

VHV supplied a variety of equipment for the project, including new sand bunkers, belt conveyors for used sand and finished sand, as well as scraper plows and dedusting connections. Among the elements supplied were 76 belt conveyors and a cover belt conveyor GB1000.

The Carat 610 was commissioned in March 2024 at Honda’s site in Tochigi, Japan. This cell is being used for research and development (R&D). Honda is conducting controlled experiments under different casting conditions to ensure and improve the quality of their end products. “Several parameters such as the casting temperature, the pressure, the casting speed, and the cooling rate can be varied in order to examine their effects on the properties of the parts,” says Cornel Mendler. 

The use of various fully-automated peripheral devices, such as spray robots for applying release agents, removal robots for lifting the parts from the molds, trimming presses for removing casting flashes and the cooling basin for regulating cooling processes, enables precise control of the entire casting process and helps to achieve reproducible results. “The R&D cell makes it possible to test process innovations and newly developed parts quickly and efficiently. This rigorous testing allows us to optimize our processes,” says Honda representative. “The expertise and experience that we gain in Japan will be shared across our production network in North America to support our electrified future.” 

The first Carat 610 cells have already been installed at Honda’s Anna Engine Plant and production is ramping up. “This project is a global cooperation between our teams in Japan and the US,” says Cornel Mendler. “Thanks to our worldwide setup, we are able to work closely with our customers and supply them with the technologies and solutions they need for success in the changing automotive landscape.”

A groundbreaking technology

Bühler has been active in die casting for nearly 100 years and the Carat series is Bühler’s answer to the globally accelerating trend towards larger structural castings in modern car architectures. The two-platen technology with die locking forces of 10,500 to 92,000 kilonewton (kN) is specifically designed to produce large and complex parts. 

Megacastings reduce complexity in production by enabling between 70 to 100 parts to be replaced by a single die-cast part. These single-piece castings will generally be produced close to the automotive assembly line, allowing for better integration and reduced transport.

Bühler has manufacturing sites for the construction of its Carat machines in Europe, the US, and China. This unique setup enables the company to produce regionally and to be close to its customers. With more than 900 machines in operation, Bühler’s Carat series is the most successful solution on the market.

5S Injection System: A Revolution in Regenerative Technology

At the heart of the MiniGigaPress lies its true innovation: the 5S injection system, a closed-loop regenerative system featuring an auxiliary servo pump for unmatched efficiency. Recognized by the European Patent Office with the prestigious Industrial European Inventor Award 2024, this one-of-a-kind technology ensures total control over pressure and speed, providing the dynamic force required to fill even the most complex and demanding molds.

Key Features of the 5S System:

• Energy Optimization: Lower energy consumption through energy regeneration during the production cycle.

• Precision Control: Continuous monitoring of pressure and speed parameters, improving final product quality.

• High Dynamic Force: Enables precise and rapid filling of intricate molds.

• Operational Efficiency: Faster, more consistent production cycles with reduced waste.

Summary in Bullet Points:

Revolutionizing Vehicle Manufacturing through Advanced Casting Techniques and Material Innovations

1. The Future of Vehicle Production

• Sandy Munro emphasizes the significance of casting technologies and new material sciences in the future of vehicle manufacturing.

• The focus is on cost optimization, efficiency, and quality through innovative production techniques.

2. Giga-Casting: A Game-Changer

• Giga-castings drastically reduce the number of parts and assembly processes.

• Advantages:

  • Fewer labor requirements

  • Higher quality (Six Sigma standards)

  • 47% less factory floor space

  • 8% lower investment costs

• Challenges:

  • Some castings, particularly Tesla’s giga-castings, are too thick and over-engineered, leaving room for further optimization.

3. Material Innovations: Moving Beyond Aluminum and Steel

• Carbon fiber and high-performance plastics are emerging as viable alternatives to traditional materials.

• Plastic battery housings offer multiple advantages:

  • Built-in cooling channels

  • Lower costs

  • Better thermal management

  • Lighter weight for improved vehicle efficiency

A solution that saves space, resources and energy 

Besides short cycle times the intensive treatment in multi-surf finishers offers additional benefits. These include that the process stage pre-grinding with ceramic grinding media – a must for drag finishers – is no longer needed. This reduces the number of required machines for surface grinding and polishing to two multi-surf finishers, as opposed to three drag finishers. This results not only in savings for capital expenditures but also reduces the consumption of energy and resources and demands less space for the surface finishing operation. An additional benefit is that the processing times for costly grinding on CNC machines can be shortened by transferring some of this work to the multi-surf finisher.

Maximum process stability through visualization and digital process water management.

To ensure a maximum of process safety and stability Rösler augmented the standard equipment controls with a process visualization module. This allows the machine operators to visually monitor the individual process stages, which the work pieces undergo at any moment in time.

The cleaning and recycling of the process water from the wet surface smoothing operation is handled by a fully automatic Z 1000 centrifuge. The control panel of the centrifuge is equipped with the digital process water management module “Advanced” from Rösler Smart Solutions. This innovative, interactive software continuously monitors, records and evaluates up to 14 process parameters, for example, the compound concentration, the pH value, the microbiological load, etc. As soon as one or several of these parameters drift out of the pre-defined range, such discrepancies are displayed. In addition, the operators obtain easy-to-understand recommendations for immediate corrective action. This allows employees with no special knowledge and training to quickly adjust the process water parameters to the pre-defined values and thus ensure a consistently high product quality. Moreover, the continuous recording of the parameters over a longer period of time provides a clear indication as to when the process water quality has deteriorated to a point where it must be replaced with new water. This results in substantial water and compound savings and guarantees that the product quality does not suffer. Finally, the continuous recording of the process water parameters can also be used as proof of the process quality and stability for quality audits and documentation purposes.

Future-Proof Through Modular Design

A planned expansion phase will allow existing production systems to be adapted for new part types. This flexible solution ensures that both current and future product generations can be efficiently manufactured—an essential advantage in a dynamic market environment.

With this innovative project, R. Scheuchl GmbH demonstrates how state-of-the-art technologies and flexible concepts can create tailored solutions that deliver maximum efficiency and quality. R. Scheuchl GmbH ultimately impresses customers with a combination of superior and reliable technology compared to local competitors, as well as attractive pricing and location advantages provided by its local branch.

R. Scheuchl GmbH: Over 60 Years of Innovation and Tradition

Since its founding in 1962 by Richard Scheuchl, R. Scheuchl GmbH has been synonymous with innovation and customized solutions in foundry technology, process engineering, energy technology, and 3D printing.

The medium-sized company employs around 250 people across its locations in Ortenburgand Shenyang (China), and is one of the leading international providers in foundry technology.

From consultation and design to installation and comprehensive after-sales service, Scheuchl offers end-to-end solutions tailored to its customers’ needs in aluminium and grey cast iron foundries. The product range includes everything from manual to fully automated systems, covering the entire value stream. This includes casting, cooling, core removal, sawing, deburring, milling, and cleaning processes, as well as advanced technologies such as arc-wire coating and the regeneration of inorganic sand.

Additionally, Scheuchl is a specialist in handling 3D-printed sand cores, including semi-automated core extraction from production boxes, robot-guided cleaning, and precise quality control.

With over 60 years of experience and a strong focus on quality and customer satisfaction, R. Scheuchl GmbH is a trusted partner for cutting-edge solutions in foundry technology.

Laempe presents the world's most efficient 3D sand printer

With their bidirectional printing and high printing speeds, Laempe 3D printers are the most efficient core sand printers in the world. The design is suitable for casting and utilises established industry standards. In addition, the entire value chain was always taken into account in the system. This begins with raw material storage and moulding material preparation and continues through to the actual printing, unpacking, cleaning and measuring of the printed components. In addition, the Laempe 3D printing line is ‘open’, meaning that customers are not tied to specific raw material suppliers. Even the single printer is designed in such a way that it can be expanded into a fully automated solution at any time - and at competitive costs - this modular approach is unique on the market. Laempe has also developed the ‘Laempe Printing Wizard Software’, a powerful tool that optimises the slicing, scaling and morphing of print jobs.

A mid-double-digit million euro sum was invested in the development project, most of which was financed from a project with BMW Group and a substantial part of which was financed from Laempe's own capital. ‘As with any project of this size, there were uncertainties, challenges and uncertain schedules along the way - together with the customer, we were able to solve all of these tasks. We would particularly like to thank our employees and the BMW Group for the successful outcome,’ Mössner continues.

The BMW Group emphasises Laempe's performance and innovative strength, which is particularly evident in the highly automated 3D printing line. According to the car manufacturer, the technology impresses with its exceptionally high printing speed and the bidirectional printing process, which enables efficient and precise production. Thanks to the comprehensive automation solutions, the system is able to seamlessly fulfil the demanding requirements of high-volume production. This combination of technological excellence and process stability represents a decisive added value for the BMW Group and confirms Laempe as a reliable partner in manufacturing technology.

‘With our innovative 3D printing technology, we expect that many more applications can be economically transferred from classic core shooting to additive manufacturing in the future. We can therefore offer our customers and partners a real competitive advantage and a forward-looking solution that will open up new growth opportunities for us. We are the only supplier to develop and operate both core shooters and 3D printers, which means we know the cost structures of both technologies inside out,’ says Mössner.

Hybrid core production with Laempe offers maximum flexibility

With its solution, Laempe enables ‘hybrid core production’, which gives foundries the choice: classic shot cores, additively printed cores or a combination of both. Laempe also offers the flexible ‘pay per part’ model via the INACORE joint venture (partner: R.Scheuchl GmbH). The company in Ergoldsbach (Bavaria) has already had a range of core shooters and a Laempe printer for three years and supplies numerous customers with printed or shot cores.

About Laempe Mössner Sinto GmbH

Laempe Mössner Sinto GmbH is the world market leader for Core production technology in the foundry industry and covers all areas of modern core production with its comprehensive product and service portfolio. The traditional German company is a complete solution developer with its headquarters in Barleben/Meitzendorf in Saxony-Anhalt. A total of 350 people are employed at this ultra-modern production site, at the Schopfheim in the Black Forest and Mannheim branches and at the subsidiaries in Pune (India) and Beijing (China). www.laempe.com

System Functionality Overview

MiCL V1 delivers eight key functionalities to optimize core production:

1. Man-Machine Interconnection:
   Provides four user roles—operator, technician, maintainer, and manager—with fingerprint-based login for role-specific authorization and precision control over equipment operation and adjustments.  These user interfaces are depicted here:

Exchange Event - Gathering Top Auto & Comms Manufacturers

Relying on the Auto-foundry Club, which has gathered over a hundred automotive and die-casting industry experts from renowned enterprises such as Tesla, Volvo, NIO, Lixiang, XPeng, Changan, BMW, Volkswagen, Dongfeng, GM, Chery, Leapmotor, ZEEKR, Schaeffler, Magna, Nemak, Tuopu Group, Wencan, MINO, etc., the conference will offer a platform for automobile and communication manufacturers, and die-casting technology solution suppliers to exchange ideas.

An Large and Highly Influential Die-casting Conference

• The Power of Models: the Awards for the Outstanding

• Industry - Academia - Research Matching

• Expert Q&A - Solution and Analysis of Casting Defects

• Recommended Brands & Products Display

• New Product/Technology Announcement

• Social Activities to Expand Industry Resources

•  Factory & University Visit

Route 1: Phoenix Contact China Corporation

Route 2: Baowu Magnesium Technology Co., Ltd.

Route 3: Brembo (Nanjing) Automobile Components Co., Ltd.

Route 4: Nanjing Changan Automobile Co., Ltd.

Route 5: School of Mechanical Engineering, Southeast University

5 Routes, 50 People/Route, Book Now!

You can click the link: https://jsj.top/f/FQatjk?x_field_1=Foundry-Planet to complete the conference registration

Review of 2024

756 delegates participated in the congress

36 speakers and experts were invited to share their research results and latest technologies on hot topics

3 industry experts shared their insights on live broadcast, and 12,743viewers watched online

46 enterprises displayed their specific high-quality products and new achievements

For more Information, please have a look at the event page (www.diecastexpo.cn/en/congress)

This, generally 1m wide and odorless, "wallpaper" is delivered on a 25m long roll that is cut to required size and mounted vertically on the furnace wall (Fig. 1). It is fixed at the top with glue (water- and halogen free) or tape. Mica side shows to the interior of the furnace (Fig. 2). The mica coating ensures good sliding between the refractory material and the coil grout.

Slip-plane Newform Combi G is a flexible, cold formed laminate comprised of phlogopite and calcium silicate fiber with a special silicon binder. The approximately 2,3 to 2,5mm thick fiber for the isolation of induction furnaces tolerate temperatures up to 1,050°C, compensates for surface unevenness of the concrete wall which is only 2cm thin and thus reduces cavities.

Newform Foil PGM, is about 0.3mm to 0.5mm thick, glass-fiber reinforced and comprised of phlogopite, and muscovite layers glass reinforced in between. It is preferably used for smooth interior walls of the furnace to be found usually in smaller furnaces (<2ton),

Both Mica-based slip-planes further compensate for refractory movements caused by the permanently active smelt.

Whole industry chain, All materials, Whole process

Featured exhibition area:

• Magnesium casting

• Low pressure casting industry chain

• Semi-solid casting industry chain

• Extrusion casting industry chain

• High pressure casting

What to Expect: 

• Global Showcase: Explore the latest in-vogue castings with buyers from India and around the world. 

• Innovation Unveiled: Discover cutting-edge technologies and processes shaping the industry's future. 

• Future Focus: Gain insights into automation and e-mobility advancements. 

• Networking Hub: Connect with customers, suppliers, and industry leaders. 

• Cultural Immersion: Experience India’s rich art and heritage, with a special focus on the East. 

• Culinary Delights: Savor exquisite cuisine crafted by renowned chefs from the East. 

• Seamless Experience: Enjoy world-class event coordination and Bengal’s legendary hospitality. 

• Milestone Celebration: Commemorate 75 years of IIF’s innovation and excellence in the foundry industry. 

• Expansive Exhibition: Explore 150+ exhibitors across two halls, spanning 9,000 square meters. 

We look forward to your visit to the 73rd Indian Foundry Congress in Kolkata! 

2. Equipment Interconnection:

Features core box recognition to automatically import technician-defined process parameters, ensuring production consistency and stability.

3. One-Click Operation:

Guides operators through a process wizard, from startup checks to cleaning and shutdown, enhancing usability and efficiency.

4. Operating Parameter Settings:

Allows adjustments and maintenance of key parameters, including operating conditions, core-making processes, core box usage records, fault logs, and wear part lifespan data, ensuring comprehensive and accurate record-keeping.

5. Intelligent Production Management:

Incorporates advanced controls, such as raw sand temperature regulation, blowing temperature management, and automated curing parameter adjustments, to make production more intelligent and efficient.

6. Remote Control and Maintenance:

Allows maintenance personnel to connect remotely to on-site control systems for troubleshooting, system upgrades, and rapid recovery of equipment functionality.

7. Online Documentation:

Provides easy access to operation guides and maintenance manuals, enabling operators and technicians to quickly reference necessary documentation.

8. Data Management:

Offers ERP/MES data interfaces with reporting and analytics features for personnel login data, operation times, production output, energy consumption, fault diagnostics, and process parameters. Managers can receive text message updates on production shifts for enhanced oversight.

Conclusion

The Mingzhi Intelligent Core Control System (MiCL V1) successfully integrates man-machine interconnection and data processing, significantly improving the precision, efficiency, and environmental compatibility of core production equipment. This system leads the industry toward environmentally friendly, high-efficiency, and intelligent production, providing clients with superior solutions for transitioning and upgrading their core production processes.

Looking ahead, Mingzhi Technology plans to enhance the system with adaptive adjustment and control capabilities across various working environments, paving the way for MiCL V2 and the full realization of artificial intelligence-driven production control.

For more information on MiCL and all our intelligent production solutions, please contact us: info.leipzig @mingzh-tech.eu

Student contributions

The program was particularly enriched by the short presentations of the students, who presented their innovative master's theses:

 • B. Eng. Matthias Middelmann: Sandkerne im Druckguss

New approaches to the use of sand cores in foundry technology.

 • B. Eng. Annike Bossert: Recasting of wooden structures in die casting

Insight into innovative processes for replicating wood structures in die casting.

 • M. Sc. Valentin Ziegler: Influence of alloying elements on the CO2 footprint of aluminum alloys

A study highlighting sustainable production methods and the influence of materials on the ecological footprint.

The conference once again demonstrated the importance of exchanging knowledge and experiences for the future of the industry.

Six specialist areas with a wide range of topics

Visitors to the in-house exhibition can look forward to six specialist areas covering all important industries - from e-mobility and digitalization to machining technology, additive manufacturing and GROB service. GROB-WERKE thus offers a comprehensive overview of modern manufacturing technologies and their possible applications in a wide range of industries. Among other things, almost the entire range of universal machining centers, including the associated automation, will be on display. In the field of machining technology, trade visitors can look forward to the G920F⁵ and the G720F, which have been specially developed for the task of mega and giga castings and frame structure parts and will be demonstrating their skills live. The in-house exhibition is also of interest to visitors looking for machine solutions at short notice, as both new and used machines will be presented and offered for sale on site.

Part-Wall: A tribute to global cooperation and cultural diversity

The visual highlight of the trade fair will be the new "workpiece wall", where typical parts from different countries will be on display, including the Eiffel Tower and other highly symbolic exhibits. This unique presentation underlines GROB's international presence and shows the company's precision work in a completely new way.

Culinary delights and factory tours for an unforgettable experience

In keeping with the motto "Welcoming the World to Bavaria", the trade fair will be accompanied by culinary delights from all over the world, offering visitors an insight into the culinary diversity of GROB locations worldwide. In addition, twelve themed plant tours are on the program each day, providing exciting insights behind the scenes and into GROB's production processes.

Comprehensive exhibitor area and application options for every industry

Once again this year, the GROB in-house exhibition is cooperating with over 60 partner companies who will be presenting their latest products and solutions. The exhibitor area thus offers the unique opportunity to experience comprehensive industry solutions from a single source.

The in-house exhibition 2025 also places a strong focus on industry-specific applications, such as aerospace, die and mold industries, mechanical engineering, energy technology, automation and automotive. Trade visitors can look forward to practice-oriented presentations and demonstrations that illustrate the wide range of possible applications for GROB technologies in these areas.

The GROB Open House offers visitors the unique opportunity to experience the latest developments, pioneering technologies and exciting networking opportunities in a modern, international trade fair environment. Interested visitors can already register for the Open House 2025 at the following link: https://event.grobgroup.com/hausmesse/en/

Source: © GROB-WERKE GmbH & Co. KG 

Decarbonization and Climate Neutrality by 2045 - Investment in Two New Electric Crucible Furnaces

With the vision of being the best foundry for  the world, Fritz Winter focuses on holistic solutions rather than quick fixes. Since 2013, the company has complied with reporting obligations under the emissions trading system, forming the foundation for its comprehensive decarbonization strategies.

A key focus has been heat recovery to address the high thermal energy demand in production halls, despite continuous heat generation from melting processes. The company prioritized heat recovery and invited experts for a "concept competition" to develop a holistic approach for future melting operations.

The winning solution features two new electric crucible furnaces with a combined melting capacity of 30 tons, recently inaugurated in the so-called “Cathedral.” This facility reduces CO₂ emissions by 43,000 tons and cuts reliance on fossil fuels like coke. Additionally, it ensures the sustainable availability of recycled materials, particularly in light of the evolving raw material landscape in steel production.

Responsibility, Passion for Change, and Excellence

Driven by a deep sense of responsibility toward future generations, Fritz Winter has initiated this sustainable transformation with strong support from its workforce. Discussions with leaders Thomas von Reth, Markus Semmler, and Christoph Helfenbein underscore how deeply this spirit is embedded in the company’s culture, shaping its actions and partnerships with those who share the same passion for change and excellence.

About Fritz Winter

Fritz Winter Eisengießerei GmbH & Co. KG, headquartered in Stadtallendorf, Germany, is a global leader in iron casting. Founded in 1951, the company has become one of Europe’s premier foundries, specializing in the automotive and mechanical engineering industries.

Fritz Winter’s core expertise lies in producing components made of grey cast iron and ductile iron. Its product range includes brake components, engine parts, and transmission housings used in vehicles from renowned global automakers. Notably, 100% of the raw materials used in production are recycled scrap, underscoring the company’s commitment to sustainability and energy efficiency.

In addition to innovative technologies for improving cast component properties, Fritz Winter invests in digital production processes and automation to further enhance efficiency and quality. The company operates modern facilities designed for energy-efficient and resource-saving production, with a strong emphasis on reducing CO₂ emissions.

Fritz Winter’s dedication to quality, innovation, and environmental responsibility makes it a trusted partner in the automotive industry and beyond.

The EV components industry in Vietnam is also gaining momentum. According to Dinh Nguyen Uyen Nhung, head of sales at Bühler Vietnam, many of Bühler’s clients in Vietnam – foreign investors from Taiwan, South Korea, and Germany – manufacture parts and equipment for global EV makers.

Bühler’s solutions, such as high-pressure aluminum die casting, enable the production of lightweight aluminum components for EVs, significantly reducing vehicle weight.

For instance, an aluminum chassis weighs approximately 54 kilograms, compared to 368 kilograms for a steel equivalent, Bühler Southeast Asia director advanced materials Rafael Diem explained.

Bühler also offers advanced wet grinding solutions to reduce particle size from 100 micrometers to nanometer scales, with energy consumption less than 50% of conventional technologies. This is vital for producing high-performance lithium-ion batteries and specialized body coatings for EVs.

Moreover, Bühler plans to introduce vacuum thin-film coating technology, critical for semiconductor and sensor production, to Vietnam. Diem highlighted this as a core technology for developing autonomous EVs, the next frontier in automotive innovation.

Bühler supports EV OEMs, including new market entrants, throughout the production process, from designing manufacturing lines to providing equipment and installation guidance. Its engineers and technology experts remain involved until products meet initial design specifications and offer lifetime support for its solutions.

“Not only foreign-invested enterprises but also Vietnamese companies, with Bühler’s advanced technologies and technical support, can participate in the global EV supply chain,” Nhung affirmed.

With operations in over 140 countries, Bühler has the expertise to deploy international engineers to assist its Vietnamese clients. Simultaneously, Bühler is investing in local talent, training engineers in design, automation, technology, and project management.

“The local workforce we train will be a crucial addition to Vietnam’s growing EV supply chain,” Diem added.

Source: www.theinvestor.vn by Thai Ha

GTK Kassel: A Key Partner

The Foundry Technology Group at the University of Kassel (GTK) played a critical role in this project. Their expertise supported YIZUMI and MAGMA in refining and validating the thixomolding process. Together, they investigated parameters such as injection speed, melt temperature, and pressure to determine optimal conditions for complex geometries.

A complex, box-shaped demonstration model illustrated that optimized settings prevent defects such as porosity and air entrapment while maintaining consistent material flow.

Sustainable Energy Efficiency

Compared to traditional methods, thixomolding reduces CO₂ emissions primarily through lower energy consumption by the hydraulic systems and mold temperature regulation. Initial tests measured energy consumption at only 1.08 to 1.26 kWh per kilogram of cast AZ91—a remarkably low value.

Future Outlook: Advancing Efficiency

Looking ahead, YIZUMI plans to develop a new generation of thixomolding machines featuring larger, energy-efficient servo pumps to further reduce CO₂ emissions. Through continuous innovation, the adoption of digital twin simulations, and improved process designs, YIZUMI ensures that its thixomolding technology remains at the forefront of sustainable magnesium casting solutions.

Adding Intelligence

Quaker Houghton has developed a platform specifically designed to address these challenges, enabling manufacturers to benefit from the optimization of fluids and processes.

QH FLUID INTELLIGENCE™ offers real-time monitoring and control of fluid performance and costs, providing quick, precise, and actionable insights. The solution is customizable, scalable, and easily integrated into production operations, reducing waste, risk, and overall operating costs.

The platform combines four key elements: Quaker Houghton's top-tier fluids, application expertise, hardware, and software. As for the hardware, the QH FLUIDMONITOR™ family uses proprietary sensor technologies for automatic real-time measurement of critical fluid and process parameters, reducing the need for manual sampling and analysis. The QH FLUIDCONTROL™ hardware family integrates proprietary sensors and controllers for automatic measurement and physical control of critical fluid and process parameters.

These hardware families work in tandem with the third element, QH FLUIDTREND™, an intuitive, user-friendly software that displays real-time and historical data and analytics from QH FLUIDMONITOR™ and QH FLUIDCONTROL™. QH FLUIDTREND™ provides manufacturers not just with data, but with insights into optimizing fluids and processes, improving the predictability of results, which is highly valued by all manufacturers.

The combined elements of the QH FLUID INTELLIGENCE™ platform deliver insights that help with three words every engineer knows well: measure, control, optimize:

- Leverage precise and effective automation to measure key parameters for fluid performance;
- Control these parameters using reliable automation technology; and
- Use data to gain insights into optimizing fluids and processes.

The end result is a predictable, tangible outcome such as improved productivity, longer equipment and tool life, optimized labor efficiency, enhanced health and safety, and in some cases, even improved sustainability. Ultimately, manufacturers can further reduce their total operating costs with the QH FLUID INTELLIGENCE™ platform—an absolute necessity in today’s competitive and inflationary environment.

LHN 100-350 Luitpoldhütte at a glance:

• Width: 8.80 meters
• Depth (Length): 7.67 meters
• Height: 6.40 meters plus 0.5 meters foundation
• Total height with sand silos: 13.8 meters plus 0.5 meters foundation
• Total weight (including core box): approx. 90 tons
This is not Laempe's first project involving a gigantic core shooting machine: In 2022, Laempe built a core shooting machine of the LHL200-1700 type, which, with a shot volume of 1,700 liters and sand cores weighing up to 2.5 tons, also set new standards in the industry. The cores produced with the LHL200-1700 are used by the customer as form parts for casting ship engine components in their foundry.

About Laempe Mössner Sinto GmbH

Laempe Mössner Sinto GmbH is the world market leader in core shooters for the foundry industry and covers all areas of modern core manufacturing with its comprehensive product and service portfolio. The traditional German company is a complete solution developer headquartered in Barleben/Meitzendorf, Saxony-Anhalt. A total of 380 employees work at this state-of-the-art production site, the branches in Schopfheim in the Black Forest and Mannheim, and the subsidiaries in Pune (India) and Beijing (China). www.laempe.com 

About Luitpoldhütte GmbH

Luitpoldhütte GmbH is a medium-sized foundry based in Amberg in the Upper Palatinate region of Bavaria. The company, over 140 years old, produces high-quality cast parts in small to medium series in gray cast iron, spheroidal graphite iron, and compacted graphite iron. Cast parts weighing up to 1 ton per piece are produced using the machine molding process. The main customers are in the agricultural machinery, engine construction, construction machinery, and compressor industries. www.luitpoldhuette.de 

Dosing that makes daily tasks much simpler.

Space saving isn’t the only reason why Handtmann chose the Westomat Duo. There’s much more to this small but mighty furnace!

With two potential openings for the riser tube, sampling can be carried out with greater speed and ease, using the riser tube opening not in operation.

Heiko Blei adds: “On top of these benefits, Westomat Duo’s pneumatic base means we simply ‘lift and tilt’ - no chassis or rails are needed for positioning. It’s very easy to operate.”

A sustainable partnership. In more ways than one.

With five StrikoMelter melting furnaces, fifteen Westomat Classic and four Westomat Duo dosing furnaces already in operation at Annaberg, and a relationship spanning over 20 years, Handtmann and StrikoWestofen’ s partnership has stood the test of time. For good reason.  

Heiko Blei comments: “We are innovators. So is StrikoWestofen. We know they will always help us meet the needs of our customers – however those needs change over the years. The excellent technical support we receive is part of that. As is their commitment to energy saving. It’s built into their furnaces and their ethos as a business. For us, the Handtmann light metal casting division seeking to CO2-neutral by 2039, this is hugely valuable. I’ve no doubt we will continue to work with StrikoWestofen for many more years to come.”

The sixth generation of electric drive in the New Class vehicles will achieve up to 30 percent more range and 30 percent shorter charging times, as well as 30 percent greater efficiency compared to the current generation of vehicles.

The center housing for the electric drive motor is a key cast component of the electric drive system. It houses the core components of the electric motor: the rotor, stator, gearbox and inverter, which are manufactured at BMW Group Steyr and compactly installed in the Landshut housing.

Bühler Carat 610

Handtmann is entering the production of large structural parts with the successful commissioning of a Carat 610 extended from Bühler AG with a clamping force of 61,000 kN and a shot weight of up to 128 kg of aluminum.

For example, large battery casings or frames up to two meters long can be produced in aluminum for electric vehicles. Even complete front or rear sections of a car can be cast in a single piece. Handtmann has already launched the first projects with German carmakers.

With this investment, Handtmann is demonstrating its entrepreneurial spirit and innovative orientation. Megacasting is an important component of the Handtmann strategy for supporting its customers in the transformation and is deliberately being established at the headquarters in Biberach in order to strengthen the competitiveness of the German automotive industry. Investments in new processes and technologies are the key to ensuring long-term growth, innovation and competitiveness in Germany and Europe.

Megacasting will enable Handtmann to enter new product areas. In line with the motto “We deliver transformation”, Handtmann will continue to increase its competitiveness and reposition itself as a reliable die caster and development partner with over 150 years of experience.

Dirk Seckler (Managing Director Sales and Technical Development, Light Metal Casting division): “We recognized early on that we have to transform ourselves from a pure ‘built-to-print’ to an innovative competence and solution provider. This also includes actively shaping the transformation through innovation. By entering the megacasting, Handtmann is taking on a pioneering role. We are the competent partner for our customers in the transformation of the automotive industry.”

To commission the new megacasting plant, the complete casting cell and the upstream and downstream processes in production were realigned and optimally coordinated. This is a basic prerequisite for implementing efficient production.

„This marks a turningpoint in vehicle production“

Heiko Pfeiffer (Executive Vice President Production, Light Metal Casting Division): “The introduction of megacasting in the automotive industry marks a turning point in vehicle production. The ability to produce large and complex structural components in a single casting allows us to shorten production time, improve material efficiency and increase the structural integrity of vehicles. Megacasting is a key driver of innovation and competitive advantage in modern production processes.”

The advantages of large components cast in a single piece primarily include reduced manufacturing complexity with lower purchasing and logistics costs. Production process steps are reduced and labor-intensive joining and finishing steps such as welding and milling are avoided. Weight in the body is saved, which is particularly relevant for electric vehicles. Megacasting is also of interest from a sustainability perspective, because larger components made from a single material offer advantages in terms of vehicle recycling.

“We extend a warm welcome to Nicole and Xavier, and we are confident that their extensive expertise and insights from the industry will greatly enhance EICF's mission to advance the investment casting industry throughout Europe and beyond”, so the official statement. 

“As we move forward, we eagerly anticipate the fresh perspectives and innovative ideas they will bring to our discussions. Together, we will continue to promote growth, resilience, and sustainability within our sector.” 

The company's technological openness is evident in Landshut. The plant is characterized by a high degree of production flexibility. In addition to the ongoing transformation and the production of components for battery-electric vehicles, Landshut continues to manufacture components for efficient combustion-engine vehicles, such as cylinder heads, crankcases and drive shafts. The plant is a center of innovation and is highly skilled in the latest manufacturing technologies. Landshut has further developed its own casting process, the injector casting process, for the next generation of housings. This innovative process not only guarantees optimal mechanical properties of the casting, but also reduces energy consumption, CO2 emissions and the use of resources. The Landshut plant is therefore making an important contribution to sustainability.

Outlook for the New Class The all-electric New Class will start production at the end of 2025, initially with an X model at the Debrecen plant in Hungary. The Munich plant will follow shortly afterwards with the sporty sedan. The high-voltage batteries for the New Class vehicles produced in the Bavarian plants of the BMW Group will in future be manufactured at the Irlbach-Straßkirchen site in Lower Bavaria.

A Proven Product

Although the QH FLUID INTELLIGENCE™ platform is a relatively new market launch for Quaker Houghton, several large manufacturers have already successfully implemented it—and the results are impressive. A global automotive company that utilized QH FLUID INTELLIGENCE™ to optimize fluids in its grinding processes saved $300,000 per year, reduced downtime by 75%, and improved productivity by 1,000 hours annually.

In the aerospace sector, a manufacturer of wing ribs has benefitted in multiple ways from QH FLUID INTELLIGENCE™. By employing the platform, the company saves manual labor in filling and maintaining coolant, extends coolant life, reduces waste and downtime during coolant changeovers, improves tool life, and reduces defects as fluid concentration remains consistent.

The list of industry segments interested in the QH FLUID INTELLIGENCE™ platform and its applications is long—from conversion coatings for surface treatments to aluminum hot rolling, steel cold rolling, and a variety of metalworking applications.

The Hype around Giga-/Megacastings

In addressing the strategic thinking of the company, Norican highlights the complexity of single-piece mega castings compared to multipart solutions, adapting to the demands of both the European and Chinese markets. The Smart platform Toggle Free (TFs) series of die-casting machines cover from 1,400t to 11,000t clamping force, as flexibility is crucial and involves more than just size.

Developing Markets and 24/7 Service

Mr. Wei sees significant opportunities for Norican as it expands its presence across Asia, exploring new markets in Thailand, Indonesia, Vietnam, Malaysia, in which Norican has created a new region in SEA. This expansion presents a vast aftermarket field alongside traditional new business.

The visit consistently demonstrated the company’s strong focus on aftermarket and sustainability. Norican prioritizes high-end market segments to ensure sustainable success, combining European technology with responsive Chinese service, offering 24/7 availability. This approach is particularly vital as the Chinese market matures, with increasing emphasis on sustainability and quality. Our host takes great pride in his team, who understand that logistics and speed are critical, especially when it comes to spare parts.

We had an exceptional visit to Changzhou, delving into the manufacturing world of the Norican Group in China. Our heartfelt thanks to Wei Baohua, Senior Vice President China Northeast Aisa, and his team for their extraordinary hospitality and insightful exchanges. We return to Europe inspired by their commitment, inspiration, and opportunities in the transformation of the foundry industry, wishing them continued success!

Calderys’ safe. program

Calderys safe.day is named after the group’s safety program: safe. launched In 2023 during the first edition of the safe.day which gathered the whole newly-combined company. The safe. Program aims to maintain a strong health and safety culture across our business. It is structured around four pillars: 

Safety First: Safety is part of the company’s DNA. Employees are encouraged to take the time to do things properly and halt operations if safety conditions do not meet the group’s policies and protocols. 

Advancing Communication: Effective and transparent communication is encouraged between co-workers about the company standards and protocols and about potential dangers. It is vital for continuous improvement.

Fostering Collaboration: Health and safety are promoted as a collective effort and shared commitment. Employees are urged to intervene in high-risk situations for the benefit of themselves and their teammates

Encouraging Ownership: Everyone is accountable for workplace health and safety, whatever their role. Employees are encouraged to actively engage and visibly commit to create an incident and injury-free environment.

“I am convinced that this plant will develop into a vibrant center of our production activities and that we have made an excellent choice with Ciudad Juárez – on behalf of the management, I would like to thank everyone involved in the successful implementation of this project. First and foremost, I would like to mention Marcelino Espelosin and his team México, who made the successful realization of this ambitious project possible. Also the entire US team of Kurtz Ersa, Inc. as well as the German Ersa and Kurtz colleagues, who have contributed significantly to the establishment of production here with tireless commitment,” said Albrecht Beck,

before handing over the microphone to Vincent and Rainer Kurtz, who, as representatives of the Kurtz shareholder families, emphasized the strategic importance of the project for the Kurtz Ersa Group. The words of welcome were followed by the traditional ribbon-cutting ceremony, factory tour, festive buffet and live music from a mariachi band, before numerous customers were able to immerse themselves directly in the performance capabilities of Kurtz Ersa systems on the following Technology Day.

Flexibility amidst geopolitical challenges

SAVELLI's strong position in the global market is a result of its ability to flexibly adapt to the current geopolitical challenges and align with leading multinational corporations investing in new foundry facilities across countries like Mexico, Poland, Germany, Bosnia, Turkey, and the United Kingdom.

Companies such as Brembo, MAT Foundry Group, Fritz Winter Eisengießerei, Castings PLC-William Lee, PMP Industries, and Elginkan-Odöksan have chosen SAVELLI and its advanced technologies for the development of new greenfield and brownfield foundry projects.

Currently, SAVELLI, together with its subsidiary Savelli Machinery Mexico and supported by FTM (Puebla), is installing a high-performance horizontal molding line with dense sand mold boxes and the corresponding sand preparation plant for MAT Foundry Mexico in Pachuca. Additionally, a large sand preparation plant with a state-of-the-art rotary cooling drum is being set up for Brembo Mexico in Monterrey.

SAVELLI’s ability to support leading multinational companies and execute complex projects across various regions solidifies its role as a trusted partner and technological leader in the foundry industry.

About Savelli Technologies srl

Savelli Technologies S.r.l. is an Italian company with over 180 years of experience in the foundry industry, specializing in the design and manufacturing of advanced green sand molding systems. Known for its innovation and engineering expertise, Savelli provides high-performance solutions for global clients in the automotive, aerospace, and industrial sectors. With a focus on quality, efficiency, and sustainability, the company plays a key role in shaping the future of foundry technology worldwide.

For more information, visit: https://www.savelli.it 

CRANFIELD FOUNDRY IN BRIEF

Since 2019, we have been systematically building our reputation in Europe as a reliable supplier of high-quality grey and ductile iron castings. Cranfield Foundry is a modern, semi-automatic grey and ductile iron DISA foundry, built in 2019 by GEMCO ENGINEERS on an area of 8 000 square meters. Currently working in 2 shifts with total of 140 employees. We are strong advocates of KAIZEN. With more than 1,500 improvements implemented annually, we consistently enhance our quality and customer service. The KAIZEN mindset also helps us effectively drive costs down, which is reflected in our competitive pricing. We are closer than it seems. With an EUR.1 certificate, 2-3 days delivery time within Europe, and competitive, stable shipping costs, we ensure consistent deliveries and reduced transport costs for our customers. Our combination of ABP induction melting technology, a horizontal DISA 32/32, and a modern core shooter gives us flexibility needed to cover a wide range of our customers’ needs, from small to large castings.

ABOUT US - TRUSTED FOUNDRY

Our facility is designed and engineered by GEMCO – a global leader in foundry engineering. Gemco built foundries for Georg Fisher, BMW and Volvo, etc. Our manufacturing equipment is delivered by DISA and ABP. With over 2,200 moulding machines installed worldwide DISA is a global leader in foundry technology. Equally impressive is expertise of ABP with over 100 years of history in metal melting technology. In order to offer competitive price and meet our customers requirements for short lead times, low stock levels and faster response – we located our investment in sunny Macedonia. In order to be able to satisfy our customers’ requirements and growing market demand long term without increasing the cost, we work closely with The Lean Enterprise Institute, Inc.