Production-ready 4-plate technology: KRÄMER+GREBE sets a new benchmark in die-casting
There is a growing demand for increasingly complex geometries, high dimensional accuracy and cost-effective mass production. 4-plate mould technology opens up new possibilities in this regard: an additional parting line in the mould design enables complex contours, undercuts and ejector movements to be realised efficiently. The 4-plate design offers clear advantages over conventional mould concepts, particularly for large-surface structural parts and automated processes. It is regarded as a key technology for the next generation of high-precision die-cast components.
Innovative mould technology for complex components now ready for series production
The mould-making specialist KRÄMER+GREBE from Biedenkopf has set a new milestone with the successful implementation of a 4-plate mould technology on a 5,700-tonne die-casting machine. On 14 March 2025, it was demonstrated that this complex mould concept is not only technically feasible but also suitable for series production. The technology offers entirely new possibilities, particularly for sophisticated aluminium castings with thin walls and functionally optimised geometry – whilst simultaneously improving cost-effectiveness and process reliability.
At the heart of this is the development of a fourth mould plate, which not only enables additional parting lines and sprue positions, but also ensures the controlled breaking off of the sprue during mould opening. A critical moment in the cycle that demands the utmost precision and innovation in mould making. KRÄMER+GREBE has reliably implemented this process in series production through targeted technical solutions.
Efficiency through intelligent component design
The 4-plate technology allows multiple direct gates to be connected directly to functional areas of the component – rather than layouts optimised purely for flow paths. This makes it possible to reduce wall thicknesses and flow paths, control solidification and prevent potential sink marks. In practice, this means: a weight reduction of up to 20 per cent whilst maintaining component functionality, shorter cycle times and lower material consumption.
Furthermore, the proximity of the gates to the component enables early separation, which minimises the post-processing effort and increases the production speed. The ejection area can be reduced as the gate system lies in the ‘shadow’ of the component – an advantage that is particularly relevant for multi-cavity moulds and Giga-Casting components.
Innovation in detail: cooling, maintenance, process control
To meet the high demands of temperature control, KRÄMER+GREBE has developed cost-effective wear sleeves as well as 3D-printed cooling sleeves. These ensure targeted cooling of the individual sprue pipes – a crucial factor for consistent component quality. The system is complemented by a hydraulically controlled holding system, which prevents the severed sprue from slipping uncontrollably and ensures the exact removal position.
Another highlight: the fourth platen features an integrated cleaning and maintenance function, which allows wear parts to be maintained or replaced directly on the machine – a crucial factor in process reliability and system availability.
Future-proof platform for series production
With this new mould concept, KRÄMER+GREBE is rising to the challenge of manufacturing large components economically, reproducibly and to a consistently high standard of quality. The mould is designed for maximum robustness, ease of maintenance and durability. Particularly in high-pressure die-casting, where moulds are subjected to enormous thermal and mechanical stresses, every component must be manufactured with repeatable precision.
The result: a scalable, forward-looking tool concept that enables existing die-casting machines to be used more efficiently – whether for large individual components or for the parallel production of several components in a single shot. The 4-plate technology saves material, time and costs – and paves the way for new generations of aluminium die-cast products.
The team at KRÄMER+GREBE looks back with pride on the moment of the first casting – accompanied by the ‘bang’ of the successful ejection and a component that met all expectations. The experts from Biedenkopf have thus not only solved a technical challenge, but have also made a decisive contribution to the further development of modern die-casting.
The team of experts at KRÄMER+GREBE is happy to provide further information on the implementation and future projects.