Handtmann’s Roadmap for the Future of Aluminum Casting: Clear Priorities, Practical Solutions

Foundry-Planet: How do you view the current situation in the European automotive industry? What impact are market developments having on investments and customer projects?

Heiko Pfeiffer, Co-CEO Handtmann Light Metal Casting and Systems Engineering:

The European automotive industry is experiencing a period of fundamental transformation. Many of the changes we see today, however, began taking shape several years ago. We therefore continuously monitor long-term developments and assess their implications for our business.

We identified early on that the transition in the powertrain mix would be more complex than initially anticipated and aligned our company accordingly. This broad positioning allows us to adapt flexibly to changing market conditions. At present, for instance, existing programs are increasingly being extended, while fewer new projects are being launched than several years ago.

The overall environment remains difficult for the foundry industry. High energy and labor costs are coinciding with an unpredictable market situation. Making the right decisions at the right time is therefore more important than ever.

We have maintained our investment strategy even through periods of crisis and intend to continue doing so. At the same time, we carefully evaluate the long-term prospects of different technologies, products and markets, directing our investments towards areas with promising potential. Where the conditions remain uncertain, we deliberately adopt a more cautious approach.

The Handtmann Group’s broad business portfolio and family-owned structure are important advantages. Its different business divisions and markets provide stability and allow us to pursue a long-term strategy without having to respond hastily to short-term market fluctuations.

Foundry-Planet: Megacasting, modular aluminum structures and hybrid concepts are all attracting attention. Which developments do you expect to prevail, and how is the foundry’s role evolving?

Dirk Seckler:

Over the long term, no single technology will determine whether a company succeeds or fails. The companies that thrive will be those that recognize change early and develop new solutions for their customers.

Built-to-Print remains an important element of our business, providing a reliable basis for capacity utilization and economic efficiency. However, this approach alone will no longer be sufficient.

Future growth will increasingly be driven by Built-to-Specification. We bring our expertise into concept competitions and development projects at an early stage. Many of the most important decisions are made well before the first component is manufactured. Companies aiming to succeed in this field must be willing to invest in development, specialist knowledge and new concepts.

I consider megacasting a genuine revolution in vehicle manufacturing. Replacing more than 100 individual components with one highly integrated part fundamentally changes vehicle design. It reduces interfaces, simplifies processes and creates entirely new opportunities for lightweight construction.

At the same time, megacasting requires substantial capital investment. As a result, an increasing number of OEMs are establishing their own production capacities. We recognized the potential of this trend early and invested before specific customer projects had been secured. This allowed us to build valuable experience and actively contribute to the further development of the technology.

Innovation and substitution potential form a third pillar of our strategy. The question is which components currently manufactured from other materials or through different production methods could be produced using aluminum die casting in the future. We see promising opportunities in areas such as robotics and stationary energy storage systems.

Foundry-Planet: What role does wheel casting play in Handtmann’s strategic development?

Dirk Seckler:

The process developed by Handtmann makes it possible, for the first time, to manufacture aluminum wheels using die casting. This is a technological breakthrough for us and gives us access to an entirely new market.

The addressable market is twice as large as our current core business. The process also offers considerable benefits: wheel weight can be reduced by up to 30 percent, while manufacturers gain greater design freedom and additional opportunities for technical optimization.

We consequently see substantial potential for further development in this area over the coming years.

Our strategy can ultimately be divided into three pillars. Built-to-Print safeguards our established business, Built-to-Specification deepens our customer partnerships, and innovation creates opportunities in new markets.

Foundry-Planet: European industrial locations face several disadvantages. Where do you see the main strengths of the European foundry industry, particularly in comparison with China?

Heiko Pfeiffer:

International competition does not take place under equal conditions. China benefits from substantial government support, whereas foundries in Germany and elsewhere in Europe must find their own ways to remain competitive.

Nevertheless, Europe has distinct advantages, including a high degree of innovation, strong industrial value chains and extensive technological expertise. In particular, the European foundry industry remains among the global leaders when it comes to complex products, process know-how and demanding quality standards.

However, high energy prices, growing regulatory requirements and bureaucratic obstacles are placing increasing pressure on our competitiveness. We need more favorable framework conditions to encourage investment, innovation and industrial value creation.

At the National Foundry Dialogue in Berlin on 10 July 2026, representatives from industry, associations, trade unions and politics jointly presented specific demands. The challenges have been clearly identified. The next step is to make and implement the necessary decisions.

Foundry-Planet: How important are artificial intelligence, simulation and data-based process optimization to Handtmann’s strategy?

Dirk Seckler:

For us, digitalization and artificial intelligence are not passing trends. They are essential elements of our future competitiveness. We have been addressing these topics intensively for several years, establishing clear responsibilities, defining a strategy and developing a practical roadmap.

In the future, competitiveness will depend even more on how effectively companies use data and convert it into measurable improvements. Data-driven solutions increase transparency, uncover relationships and provide a more comprehensive and reliable basis for decision-making.

Artificial intelligence will accelerate this process. Nevertheless, the expertise of our employees remains fundamental. AI cannot replace their knowledge, but it can help analyze information faster, recognize patterns earlier and support better-informed decisions.

We therefore began establishing the necessary structures and expertise at an early stage, and we are already seeing the benefits today.

Heiko Pfeiffer:

“Industry is currently changing at a very dynamic pace. And that is precisely where enormous opportunities lie for the next generation of engineers.”

Foundry-Planet: What would you recommend to young engineers considering a career in the foundry industry?

Heiko Pfeiffer:

Technical knowledge remains essential. At the same time, the ability to look beyond one’s own area of specialization is becoming increasingly important. Successful engineers need to understand not only technical relationships but also their economic consequences and associated cost structures.

Digitalization will have a major influence on industrial development in the coming years. Technology and digitalization can no longer be treated as separate subjects.

My recommendation is to remain open to new areas of knowledge and develop as broad a perspective as possible. This means being professionally flexible, continuously expanding your skills and remaining open to international experiences and assignments. Industry is evolving at a very dynamic pace, creating significant opportunities for the next generation.

Dirk Seckler:

“Technologies can be acquired. But the companies that will truly succeed are those that develop their organizations and bring their employees along on the journey.”

Foundry-Planet: Which three strategic decisions should foundries make today to remain successful in 2035?

Dirk Seckler:

First, every company needs a clear vision of its future direction. Which customers does it want to serve? Which products does it intend to offer? Which technologies and machine classes will be required to succeed in the years ahead? Without this strategic clarity, making the right decisions becomes difficult.

Second, companies must invest consistently in their future, covering machinery, processes, technologies and new business areas. Transformation does not happen automatically. Businesses must actively shape change and establish the conditions necessary to make it possible.

Third, cultural change is essential. Technologies can be purchased, but long-term success depends on companies developing their organizations and involving their employees throughout the transformation process.

Flexibility, openness to new technologies and digitalization, and a genuine culture of innovation will all be decisive for future success.

Transformation does not start with machines. It starts with people.

Albert Handtmann Metallgusswerk GmbH & Co. KG is one of Europe’s leading aluminum casting specialists and belongs to the internationally active Handtmann Group, headquartered in Biberach an der Riß, Germany.

The company has expanded well beyond the traditional foundry business and now operates as a 360° solution partner. Its services cover the entire process, from development and materials expertise through prototyping to industrialization and high-volume production.

Key areas of future growth include highly integrated structural components and megacasting, new applications for aluminum die casting, and Handtmann’s proprietary die-casting process for aluminum wheels. The company is also pursuing ongoing investments in digitalization, artificial intelligence and data-driven process optimization.