Two years ago, the starting signal was given for the innovative die casting process, in which Handtmann has invested millions. About a year and a half after the groundbreaking ceremony, a series part was cast for the first time on the new megacasting machine on October 25, 2024.
Handtmann, headquartered in Biberach an der Riss, is the largest family-run light metal foundry in Europe, with five production sites worldwide in Germany, Slovakia and China.
Megacasting typically refers to the casting of very large metal parts, the production of which requires special casting techniques and machines. Internationally, megacasting is already an emerging technology, particularly in China and the USA. The die casting process has the potential to revolutionize the automotive manufacturing process.
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 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.
From the start of sales in October 2023, the new MAN eTruck will offer a daily range of 600 to 800 kilometers. And future-proof charging technology is right on board: ‘With megawatt charging technology (MCS), our MAN eTruck with its battery of up to 534 kWh can cover a range of 300 to 400 kilometers during the driver's break from driving. This corresponds to charging 10 to 80 percent of the existing battery capacity,’ explained Dr Frederik Zohm, Chief Development Officer at MAN Truck & Bus, during the official launch of the commercial vehicle charging park at the Allianz Arena. The new MAN eTruck can also be equipped with CCS charging, for example for overnight charging at depots. For greater flexibility, the CCS connection can be positioned on the right or left side of the vehicle, or on the right at the rear of the vehicle in the case of chassis. If the MCS connection, which is always positioned on the driver's side, is omitted, a combination of two CCS connections is also possible.
