Handtmann launches Megacasting at its Biberach site
Two years ago, the green light was given for the innovative die-casting process, in which Handtmann has invested millions. Around one and a half years after the ground-breaking ceremony, the first production part was cast on the new Megacasting machine on 25 October 2024.
Handtmann is the largest family-run light metal foundry in Europe, headquartered in Biberach an der Riss, with five production sites worldwide in Germany, Slovakia and China.
Megacasting typically refers to the casting of very large metal components, the production of which requires specialised casting techniques and machinery. Internationally, megacasting is already an emerging technology, particularly in China and the USA. The die-casting process has the potential to revolutionise the manufacturing of motor vehicles.
Bühler Carat 610
Handtmann is entering the production of large structural components following 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.
For electric vehicles, for example, large battery housings or frames up to two metres in length can be manufactured from aluminium. Even complete front or rear sections of a car can be cast in a single piece using this process. Handtmann has already launched its first projects with German car manufacturers.
With this investment, Handtmann is demonstrating its entrepreneurial spirit and commitment to innovation. Megacasting is a key component of Handtmann’s strategy to support its customers through the transformation process and is being deliberately established at the company’s headquarters in Biberach to strengthen the competitiveness of the German automotive industry. Investments in new processes and technologies are key to securing long-term growth, innovation and competitiveness in Germany and Europe.
Megacasting enables Handtmann to enter new product areas. In line with its guiding motto, ‘We deliver transformation’, Handtmann will further enhance its competitiveness and reposition itself as a reliable die-caster and development partner with over 150 years of experience.
Dirk Seckler, Managing Director of Sales and Technical Development, Light Metal Casting Division: “We recognised early on that we needed to transform ourselves from a purely ‘built-to-print’ supplier into an innovative provider of expertise and solutions. This also involves actively shaping transformation through innovation. By entering the Megacasting sector, Handtmann is taking on a pioneering role. We are the expert partner for our customers in the transformation of the automotive industry.”
To commission the new Megacasting plant, the entire casting cell as well as the upstream and downstream processes were reorganised and optimally coordinated within production. This is a fundamental prerequisite for achieving efficient production.
“This is a turning point in automotive production”
Heiko Pfeiffer, Managing Director of Production, Light Metal Casting Division: “The introduction of Megacasting in the automotive industry marks a turning point in vehicle production. By enabling the production of large and complex structural components in a single casting, we can reduce production time, improve material efficiency and enhance the structural integrity of vehicles. Megacasting is a key driver of innovation and competitive advantage in modern production processes.”
The advantages of large, single-piece cast components include, above all, reduced manufacturing complexity, leading to lower procurement and logistics costs. Production steps are eliminated, and labour-intensive joining and finishing processes such as welding and milling are avoided. Weight is saved in the bodywork, which is particularly relevant in the case of electric vehicles. Megacasting is also of interest from a sustainability perspective, as larger components made from a single material offer advantages in vehicle recycling.