Albert Handtmann GmbH & Co. KG: The trend is towards megacasting

The decision to adopt megacasting was a significant step that has opened up new possibilities in production and demonstrates the company’s commitment to implementing innovative solutions. Megacasting is a highly topical subject in the foundry industry, involving the production of highly integrated and complex components in a single casting process. The process offers a host of advantages, such as shorter production times, lower production costs and optimised properties of the castings. Handtmann was the first Tier 1 supplier in Europe to opt for this process. The investment in the Bühler Carat 610 machine at the Biberach plant also required changes to the infrastructure.

Two further megacasting machines will be installed in future

The company has the capacity to install two further megacasting machines in order to meet growing demand.

Handtmann has now secured orders: “We have two series production contracts due to start in 2026, although we will begin pre-series production as early as 2024,” says Stefan Kneer (Head of Design and Business Development at Handtmann). One of the new orders is for a high-voltage battery housing. With a length of 2.10 m, this breaks new ground in terms of dimensions that would have been unthinkable for die-casting just a few years ago.

But how did the decision come about to enter the Megacasting sphere as a Tier 1 supplier? The major advantage of Megacasting lies in the ability to simplify assemblies. By utilising the design freedom offered by die-cast components, individual parts are replaced and functions are integrated. This eliminates critical joining processes in manufacturing, resulting in a significantly reduced cycle time and a smaller footprint in production. Consequently, components produced using Megacasting are significantly cheaper to manufacture. Furthermore, large castings usually have greater structural stability than complex, assembled sub-assemblies.

Component testing as a development project

Before deciding to invest in Megacasting, Handtmann carried out component development as part of innovation projects. One of the components was none other than a rear sub-assembly, which replaces a conventional vehicle module comprising 97 individual parts. The die-cast component meets all requirements for rigidity, strength and crash behaviour.

Over the past few years, we have acquired in-depth development expertise, enabling us to get involved with our customers right from the very early stages of pre-development. We begin with topology optimisation, which I consider to be essential as the basis for developing a structural die-cast component. As soon as the initial CAD data is generated, the first casting simulations begin.  “Castability is a crucial consideration, particularly for large components, and must be taken into account right from the start,” says Kneer. Handtmann has carried out pre-development projects in collaboration with partner companies not only for rear axles, but also for front axles, tailgates and battery systems.

“Over the last few years, we have acquired in-depth development expertise that enables us to get involved with our customers right from the very early stages of pre-development. We start with topology optimisation, which I consider to be absolutely essential as the basis for developing a structural die-cast component. As soon as the initial CAD data is generated, the first casting simulations begin.  Castability is a crucial consideration, particularly for large components, and must be taken into account right from the start,” says Kneer. However, Handtmann has carried out pre-development projects in collaboration with partner companies not only for rear subframes, but also for front subframes, tailgates and battery systems.

Harnessing the benefits of die-casting

Beyond megacasting, Handtmann is also driving forward other innovation projects and continuously developing new components such as electronic components or structural parts, which are manufactured on a total of over 99 die-casting machines. “Megacasting is very much in vogue. But even beyond the very large components, our customers have recognised that savings can be achieved throughout the vehicle by utilising the advantages of die-casting. Driven by the need for simplification and weight reduction, particularly in the field of e-mobility, we expect a further, significant increase in the proportion of aluminium die-castings per vehicle. This opens up unprecedented opportunities for the die-casting industry. We are not only capitalising on these through innovative lightweight design, but are also working on solutions for process improvements and alloy development. “The path has been paved for us; now we must follow it and seize the opportunities,” said Kneer.

The company thus remains a key partner in the automotive supply industry, one that will continue to focus on innovation in the future and realise new projects together with its customers.

With a tradition and expertise in metal casting stretching back over 150 years, extensive technical know-how and a strong international network, Handtmann is once again demonstrating its ability to transform complex challenges into effective solutions. Further information can be found at www.handtmann.de.

About Handtmann: First-class technologies spanning five generations

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

The internationally active company, headquartered in Biberach an der Riss, can look back on a 150-year history of success and has demonstrated, through its long-standing experience and expert knowledge, its ability to transform complex challenges into viable solutions. The more than 2,300 employees at the German plants in Biberach and Annaberg, the Slovakian plants in Košice and Kechnec, and the Tianjin plant in China generated a turnover of around 597 million euros in the 2023 financial year.

Whether die-casting or permanent-mould casting, at Handtmann product strategies and problem-solving processes are seamlessly integrated.

• Utilising and integrating engineering expertise early on in the development process
• Targeted integration of expertise from both the customer and Handtmann
• Finding common ground for solving project tasks through interdisciplinary dialogue

• Complex mechanical machining as well as component and system assembly complement a consistent product strategy. Further information is available at www.handtmann.de.