This paper summary is based on the article ['The Future of Structural Components in HPDC.'] presented at the ['Bühler AG']
1. Overview:
- Title: The Future of Structural Components in HPDC.
- Author: Hermann Jacob Roos, Martin Lagler, Luis Quintana
- Publication Year: Not specified in the paper.
- Publishing Journal/Academic Society: Bühler AG
- Keywords: structural components, HPDC, die casting, automotive industry, weight reduction, thermal management, alloy selection, lightweight design, cost reduction.
2. Abstracts
The continuing quest for lighter-weight components in the automotive industry has
seen the emergence of a lucrative new market for die casting: structural components.
The demand for these large, complex components, such as shock towers and
longitudinal beams, was estimated to cover just under 6 million cars in 2018, many
with multiple structural components. Current usage is predicted to grow to nearly 9
million cars by 2025.3 But whilst these structural components offer a more rigid,
lighter solution that car makers want, the cost for longer production runs has so far
limited adoption to sports cars, luxury cars, SUVs and quality D segment saloons,
where smaller runs make economic sense. But the economics of die casting are
changing. Over the past few years, the costs of structural components have dropped
by as much as 20 percent. This paper shows how a combination of advanced
thermal management, the use of new alloys and careful product design could drive
down production costs even further. Hereby die-cast structural components get more
cost-effective for the mass car market. With new car production predicted to hit the
110 million vehicle mark in 2023¹, and with between two and six structural
components per car, these technological advances could potentially transform the
opportunity for die casters around the world. If the manufacturing chain – from die-
casting machine manufacturers, to foundries and OEMs – work together, it will be
possible.
3. Research Background:
Background of the Research Topic:
The automotive industry is continuously pursuing lighter-weight components to enhance fuel efficiency, extend battery range, and reduce emissions. This trend has led to a significant demand for structural components, creating a lucrative market for die casting. Electric mobility is rapidly expanding, with global sales more than doubling from 2 million in 2017 to 5.1 million in 2018.² Every car manufacturer aims to produce more sustainable vehicles at a lower cost, making weight reduction a key factor. Die casting of large structural components in aluminum alloys is recognized as an effective method for vehicle weight reduction, offering exceptional strength and formability compared to traditional steel structures.
Status of Existing Research:
Die-cast structural components, pioneered in the German luxury car market, are now utilized across various vehicle categories. Figure 1 illustrates the current usage of structural components in the automotive market, categorized by vehicle type (High, Medium, and Low usage) and exemplary components such as front shock towers, rear shock towers, longitudinal beams, and firewalls. S sport coupés and F luxury cars currently exhibit the highest usage, incorporating components designed for crash energy dissipation. E segment executive cars and J segment sport utility vehicles utilize die-cast components in shock towers and rocker reinforcements. D-segment large cars use die-cast parts for front shock towers and tunnel reinforcement.
Necessity of the Research:
Despite the advantages, the adoption of die-cast structural components in mass-market vehicles has been limited due to cost considerations associated with longer production runs. While investment costs for tooling are relatively low, increased tool wear leads to higher maintenance costs, making overall unit costs prohibitive for C segment medium car market and smaller mass market cars. However, the economics of die casting are evolving, with costs of structural components decreasing by up to 20% in recent years. There is a need to explore technological advancements that can further reduce production costs, making die-cast structural components more cost-effective for mass car market adoption and unlocking the potential for die casters worldwide.
4. Research Purpose and Research Questions:
Research Purpose:
This paper aims to demonstrate how advancements in thermal management, alloy selection, and product design can further reduce the production costs of die-cast structural components, enabling their broader adoption in the mass automotive market. The ultimate purpose is to identify pathways for die casting to overcome the cost barrier and become a viable solution for structural components in mass-produced vehicles.
Key Research:
The key research question is: "what advances and techniques could be deployed now, with current technology, which would enable die-casting to break the cost barrier to mass market adoption?" The paper investigates three technological areas:
- Improving productivity through thermal management.
- Utilizing new alloys to reduce process steps.
- Lightweight construction by product design.
Research Hypotheses:
The central hypothesis is that by implementing advanced thermal management, utilizing new alloys to minimize or eliminate heat treatment, and employing lightweight product design, the production cost of die-cast structural components can be significantly reduced, making them economically feasible for mass market automotive applications. Specifically, the paper hypothesizes that a combination of these approaches can achieve a cost reduction exceeding 23%, as demonstrated in a theoretical cost reduction program for a typical shock tower.
5. Research Methodology
Research Design:
This paper employs an analytical and demonstrative approach, leveraging Bühler's application knowledge and market analysis conducted by Roland Berger. It presents a theoretical cost reduction program based on calculations and industry best practices, rather than empirical experimentation. The design focuses on showcasing the potential impact of specific technological advancements on the cost-effectiveness of die-cast structural components.
Data Collection Method:
The analysis is based on Bühler’s industry experience and application knowledge gained across Europe, China, and North America. Market data and predictions are derived from a Roland Berger study (Figure 2), which considers existing, known, and projected vehicle architectures, congress presentations, and interviews with industry experts. Cost saving calculations are presented based on a typical shock tower component, utilizing a 4,400-ton machine and a two-cavity, three-plate tool setup.
Analysis Method:
The paper utilizes a cost-benefit analysis approach to evaluate the impact of thermal management, new alloys, and lightweight design on unit production costs. Cycle time reduction, die lifetime extension, and scrap rate reduction are quantified to demonstrate the cost savings achieved through improved thermal management (Figure 4 and 5). The potential cost savings from utilizing new alloys that reduce or eliminate heat treatment are also analyzed (Figure 7). Finally, the cost reduction resulting from lightweight design is assessed (Figure 8). The cumulative cost reduction from these three areas is calculated to demonstrate the overall potential for making die-cast structural components more competitive.
Research Subjects and Scope:
The research focuses on die-cast structural components, specifically using a typical automotive shock tower as a case study. The scope is limited to High Pressure Die Casting (HPDC) technology and its application in the automotive industry. The analysis considers various vehicle segments, from luxury cars to mass-market vehicles, and examines the potential for expanding the use of die-cast structural components across these segments by addressing cost barriers.
6. Main Research Results:
Key Research Results:
The paper identifies three key technological advancements that can significantly reduce the production cost of die-cast structural components:
- Improved Thermal Management: Optimizing thermal balance and incorporating targeted micro-spraying can reduce cycle times by approximately 33% (from 90 seconds to 60 seconds for a typical shock tower), extend die lifetime by 50% or more (from 80,000 to at least 120,000 cycles), and reduce scrap rates from 5% to 3%. This combination can lead to a 10% reduction in unit production costs (Figure 5).
- New Alloy Systems: Utilizing new alloy systems, such as AlMg4Fe2 or AlMg6Si2MnZr, can potentially eliminate the need for heat treatment (HT) and straightening processes, further reducing production costs. Switching to new alloys can yield an additional 10% cost reduction (Figure 7). Table 1 details the properties of Standard Structural Alloy Systems (AlSi10MnMg) compared to New Alloys (AlMg4Fe2) and High Strength Alloy Systems (AlMg6Si2MnZr). Figure 6: Possibilities of different alloy systems for Structural components. Alloy System AlSi10MnMg AlMg4Fe2 AlMg6Si2MnZr HT T7 F T5 UTM Rm[MPa] 200-240 240-260 350-380 Yield strength Rp0,2% [MPa] 120-140 120-140 230-250 Elongation A [%] 10-20 10-22 8-12
- Lightweight Product Design: Intelligent product design, such as reducing wall thickness from 2.5 mm to 1.8 mm, can achieve up to 20% weight savings. In the shock tower example, weight reduction from 4,000g to 3,600g (10% reduction) can further reduce production costs by 4% (Figure 8).
Data Interpretation:
The data presented in Figures 5, 7, and 8 demonstrates a cumulative cost reduction potential of over 23% by combining improved thermal management, new alloy utilization, and lightweight design. Figure 2 illustrates the predicted growth in the structural components market, emphasizing the increasing demand. Figure 3 highlights the potential market growth with production cost savings, suggesting a significant expansion from approximately 6 million units to 25 million units by 2030. Figure 4 visually represents the cycle time reduction achieved through better thermal management.
Figure Name List:
- Figure 1: Current usage for structural components in the automotive market
- Figure 2: Predicted growth in current structural components, 2015 to 2025
- Figure 3: Potential structural component market growth with production cost savings
- Figure 4: How better thermal management can reduce cycle times by up to a third
- Figure 5: Cost reduction using improved thermal management
- Figure 6: Possibilities of different alloy systems for Structural components.
- Figure 7: Potential cost savings from new alloys
- Figure 8: Cost saving potential by light weight design
7. Conclusion:
Summary of Key Findings:
The paper concludes that die-cast structural components have significant potential for mass automotive market adoption by addressing cost barriers. A combination of advanced thermal management, new alloy systems, and lightweight product design can achieve a substantial cost reduction of over 23%. This cost reduction is primarily driven by cycle time improvements, extended die life, reduced scrap, and elimination of post-casting processes like heat treatment and straightening.
Academic Significance of the Study:
This study highlights the importance of continuous innovation in die casting technology to meet the evolving demands of the automotive industry. It provides a framework for understanding how specific technological advancements can contribute to the economic viability of die-cast structural components in mass production. The analysis underscores the potential of HPDC to contribute to vehicle weight reduction and sustainability goals.
Practical Implications:
The findings have significant practical implications for die casting foundries, automotive OEMs, and die casting machine manufacturers. Implementing the proposed technological advancements can enable die casters to penetrate the mass market, while OEMs can benefit from cost-effective lightweighting solutions. The paper emphasizes the need for collaboration across the manufacturing chain to realize these benefits.
Limitations of the Study and Areas for Future Research:
This paper presents a theoretical cost reduction program based on calculations and industry experience. Further research could involve empirical validation of these findings through pilot production studies and real-world case studies. The analysis focuses on a typical shock tower; future research could explore the applicability of these cost reduction strategies to a wider range of structural components and different die casting processes. Additionally, investigating the long-term performance and durability of structural components produced with new alloys and lightweight designs would be valuable.
8. References:
- Wagner, Statistica, available at: https://www.statista.com/
statistics/266813/growth-of-the-global-vehicle-production-
since-2009/ - IEA (2019), "Global EV Outlook 2019", IEA, Paris, www.iea.
org/publications/reports/globalevoutlook2019/ - Roland Berger (2019), Independent research for Bühler
AG: Considers existing, known and projected architectures,
congress presentations and interviews with industry experts. - DGS award-winning casting: https://www.dgs-druckguss.
com/en/technology-and-innovation/awards
9. Copyright:
- This material is "Hermann Jacob Roos, Martin Lagler, Luis Quintana"'s paper: Based on "The Future of Structural Components in HPDC.".
- Paper Source: Not specified in the paper.
This material was summarized based on the above paper, and unauthorized use for commercial purposes is prohibited.
Copyright © 2025 CASTMAN. All rights reserved.
This paper summary is based on the article ['The Impact of Giga-Castings on Car Manufacturing and Aluminum Content'] presented at the ['Light Metal Age']
1. Overview:
- Title: The Impact of Giga-Castings on Car Manufacturing and Aluminum Content
- Author: Alicia Hartlieb and Martin Hartlieb
- Publication Year: 2023
- Publishing Journal/Academic Society: Light Metal Age (June 2023 issue, Editor's Note)
- Keywords: giga-castings, mega-castings, car manufacturing, aluminum content, automotive, castings, sheet metal, extrusions, BEVs, BIW, rheocasting, sustainability
2. Abstracts
Numerous studies, especially from Ducker-Carlisle, have shown that aluminum usage in light vehicles has been growing for decades, having surpassed 500 lbs (227 kg) per light vehicle in North America and 396 lbs (180 kg) per vehicle in Europe. Until now, castings have been the predominant product form, but in recent years and even more so in coming years, sheet and extrusion applications are showing the greatest growth rates. The main driver for aluminum use has always been lightweighting.
The accelerating electrification of vehicles has only continued aluminum's growth trend, while also changing the product mix. Historically, castings have been the predominant product form and have mainly been used in the powertrain of internal combustion engine (ICE) vehicles (primarily using secondary A380 or 319 alloys), while hybrid vehicles usually contain smaller engines and battery electric vehicles (BEVs) do not use ICEs. Now, the aluminum growth has been shifting to the car body and chassis, and for electric vehicles also to the battery trays and electric drive components. Today, these components are mostly made from sheet and extruded products with only some castings, which are often structural and, therefore, made with more sophisticated processes and cleaner aluminum alloys (either primary or secondary from clean scrap).
Currently, a higher aluminum content, especially assemblies of sheet metal and extrusions, means higher costs. Additionally, if primary aluminum is used, it also means a higher carbon footprint. OEMs and their suppliers have therefore been working on lowering both the material and processing costs of their components, while improving production quality and enhancing sustainability, i.e., increasing recycling content in all types of aluminum parts.¹
In the last few years, a new trend is starting to catch on. Initiated by Tesla, the trend involves utilizing giga-castings (also referred to by some OEMs as "mega-castings"). These large cast structural components are able to integrate many different parts into a single ultra-large casting. This could not only impact the way cars are manufactured and the utilization of aluminum in general, but also affect the content of different product forms (castings, sheet, and extrusions) in light vehicles. In other words, it could spur new growth for castings and potentially slow down the growth of sheet and extrusions.
3. Research Background:
Background of the Research Topic:
Aluminum usage in light vehicles has been increasing for decades, driven by lightweighting. Historically, castings were the predominant aluminum product form, mainly used in powertrain of internal combustion engine (ICE) vehicles. However, with the accelerating electrification of vehicles, aluminum application is shifting towards car body and chassis, battery trays, and electric drive components, predominantly using sheet and extrusions. Higher aluminum content, especially with sheet metal and extrusions, increases costs and carbon footprint, prompting OEMs to seek cost reduction, quality improvement, and enhanced sustainability through increased recycling content.
Status of Existing Research:
Studies from Ducker-Carlisle have indicated the growing trend of aluminum usage in light vehicles, surpassing 500 lbs (227 kg) per light vehicle in North America and 396 lbs (180 kg) per vehicle in Europe. These studies highlight the historical predominance of castings, but also the recent growth in sheet and extrusion applications.
Necessity of the Research:
A new trend of utilizing giga-castings (or mega-castings), initiated by Tesla, is emerging. These large cast structural components can integrate numerous parts into a single casting, potentially revolutionizing car manufacturing, aluminum utilization, and the product form mix in light vehicles. Understanding the impact of giga-castings on car manufacturing and aluminum content is crucial for the automotive industry.
4. Research Purpose and Research Questions:
Research Purpose:
The paper aims to analyze the impact of giga-castings on car manufacturing processes and aluminum content within vehicles. It explores the potential of giga-castings to transform traditional car body design and manufacturing, and assesses the benefits and challenges associated with this technology.
Key Research:
The key research questions addressed in this paper are:
- How do giga-castings revolutionize traditional car body (unibody) design and streamline manufacturing?
- What are the benefits of using giga-castings in car manufacturing, such as component reduction, weight reduction, and simplified assembly?
- What are the downsides and challenges associated with giga-castings, including repairability, tolerance control, and casting quality?
- How do giga-castings impact the utilization of different aluminum product forms (castings, sheet, extrusions) and steel sheet metal stampings in vehicles?
- What is the potential of rheocasting as a solution to address some of the challenges in producing giga-castings?
Research Hypotheses:
Not explicitly stated in the paper. However, implicitly, the paper explores the hypothesis that giga-castings represent a significant shift in automotive manufacturing with both considerable advantages and new challenges compared to traditional methods using sheet metal assemblies and smaller castings.
5. Research Methodology
Research Design:
This paper employs a descriptive and analytical approach, based on industry observation and analysis of emerging trends in automotive manufacturing, particularly the adoption of giga-castings. It is presented as an industry overview rather than a strictly academic research paper.
Data Collection Method:
The analysis is based on industry reports, case studies of OEMs like Tesla, Volvo, and Polestar, and general knowledge of automotive manufacturing and die casting technologies. Specific sources are cited as references throughout the text.
Analysis Method:
The paper uses a qualitative analysis method, discussing the benefits, downsides, and challenges of giga-castings based on current industry practices and expert opinions. It compares giga-casting technology to traditional methods and explores the potential impacts on material usage and manufacturing processes.
Research Subjects and Scope:
The scope of the paper is focused on the application of giga-castings in the automotive industry, specifically for car body structures (BIW), chassis components, and battery trays in light vehicles, including both Battery Electric Vehicles (BEVs) and vehicles with Internal Combustion Engines (ICE).
6. Main Research Results:
Key Research Results:
- Revolutionizing Car Manufacturing: Tesla's use of two giga-castings in Model Y replaced 171 parts, eliminated 1,600 welds, and removed 300 robots, significantly reducing capital investment and floorspace.
- Benefits of Giga-Castings:
- Component Reduction: Integrates numerous stamped sheet components and smaller castings into one large casting.
- Weight Reduction: Reduces overall vehicle weight, especially beneficial for BEVs to increase range and efficiency.
- Simplified Assembly: Simplifies vehicle bill of material, making manufacturing and assembly easier and quicker.
- Reduced Capital Investment: Greenfield facilities designed for giga-casting benefit from reduced assembly space and time.
- Supply Chain Logistics: Shortened assembly line and reduced welding.
- Downsides and Challenges of Giga-Castings:
- Repairability: Damage to a giga-casting necessitates replacement of the entire casting, which is cost-prohibitive.
- Tolerance Control: Maintaining tight tolerances during manufacturing is challenging due to varying wall thicknesses and cooling rates, leading to distortions. Complex straightening systems are required.
- Casting Quality: Achieving defect-free large structural castings is extremely challenging, leading to potentially high scrap rates.
- Die Challenges: Dies for giga-castings are huge, expensive, and have limited die life compared to stamping dies.
- Impact on Material Usage:
- Giga-castings may slightly impact aluminum sheet content growth but will convert some steel sheet to aluminum castings.
- Extrusions are less affected, especially for components like crash boxes. Battery trays might see some replacement of extrusions with giga-castings.
- Overall, giga-castings are expected to increase total aluminum content in vehicles, taking share from steel sheet stampings.
- Rheocasting as a Solution: Rheocasting (semi-solid casting) is considered a potential solution to address giga-casting challenges, offering benefits like improved part complexity, increased flow length, extended die life, reduced machine size requirements, and enhanced alloy and sustainability options.
Data Interpretation:
Giga-castings represent a paradigm shift in automotive body structure manufacturing. While offering significant advantages in terms of manufacturing efficiency and vehicle performance, they also introduce new challenges related to production, quality control, and repair. The industry is actively exploring solutions like rheocasting to mitigate these challenges and fully realize the potential of giga-casting technology. The impact on material usage suggests a potential increase in overall aluminum content in vehicles, with a shift from sheet and steel to castings in certain structural applications.
Figure Name List:
- Figure 1: Current usage for structural components in the automotive market
- Figure 2: Predicted growth in current structural components, 2015 to 2025
- Figure 3: Potential structural component market growth with production cost savings
- Figure 4: How better thermal management can reduce cycle times by up to a third
7. Conclusion:
Summary of Key Findings:
Giga-castings are revolutionizing car body designs and manufacturing in the automotive industry. They are primarily used for front and rear underbody and battery trays, replacing aluminum and steel sheet metal, smaller castings, and extrusions. Giga-castings offer benefits like component reduction, weight reduction, and simplified assembly, but also pose challenges in repairability, tolerance control, and casting quality. Rheocasting is being explored as a potential solution to overcome some of these challenges and enhance sustainability through increased recycled content. The overall impact of giga-castings is positive for aluminum growth in vehicles, with a likely shift in material usage patterns.
Academic Significance of the Study:
This paper provides a timely overview and analysis of the emerging trend of giga-castings in the automotive industry. It highlights the technological advancements and challenges associated with this manufacturing innovation, contributing to the understanding of evolving automotive manufacturing techniques and their impact on material selection and vehicle design.
Practical Implications:
For automotive OEMs, giga-castings offer a pathway to streamline manufacturing, reduce costs, and improve vehicle performance, particularly for electric vehicles. However, it necessitates significant capital investment in new equipment and expertise in large-scale casting processes. Suppliers need to adapt to the demands of giga-casting production, addressing challenges in die manufacturing, casting quality, and post-processing. The shift towards giga-castings also has implications for the aluminum industry, potentially increasing demand for specific alloys and recycled aluminum content.
Limitations of the Study and Areas for Future Research:
This paper is based on an overview of current industry trends and lacks in-depth quantitative data or technical analysis. Future research could focus on:
- Detailed technical studies on the metallurgy and processing of giga-cast alloys.
- Quantitative analysis of cost savings and performance improvements achieved through giga-casting.
- Investigation of advanced process control and quality assurance methods for giga-casting production.
- Comparative life cycle assessments of vehicles manufactured with giga-castings versus traditional methods.
- Further exploration of rheocasting and other advanced casting techniques for giga-casting applications.
8. References:
- Hart, C., A. Afseth, and B. Zuidema, "Aluminum Value in Battery Electric Vehicles,” The Aluminum Association, 2022.
- Abraham, A.K., "Automotive Materials in an Evolving Landscape,” Ducker Carlisle, January 24, 2023.
- Loots, W., "Tesla Giga Casting,” Driven, January 1, 2023.
- Schuh, G., G. Bergweiler, L. Dworog, and F. Fiedler, "Die Karosserie aus dem Aluminium-Druckguss / Opportunities and Risks of Mega-Casting in Automotive Production – The Aluminum Die-Casted Body in White,” Düsseldorf: VDI Fachmedien, September 2022, www.researchgate.net/publication/363880399.
- Wärmefjord, K., J. Hansen, and R. Söderberg, "Challenges in Geometry Assurance of Megacasting in the Automotive Industry,” ASME, Journal Computing and Information Science in Engineering, Vol. 23, No. 6, December 2023, https://doi.org/10.1115/1.4062269.
- "Giga Presses – the giant die casts that are reshaping car manufacturing,” Reuters/Automotive News Europe, February 10, 2023.
- Volk, W., "Gigacasting ist geeignet, den Karosseriebau neu zu denken,” Automobil-Produktion, February 3, 2022.
- Carney, D., "Volvo Joins Tesla in the Giga Press Club," Design News, Mar 14, 2022.
- Bergeron, S., M. Hartlieb, P. Jansson, and J.-C. Tawil, “Rheocasting Structural Components," Die Casting Engineer, May 2023, pp. 24-30.
9. Copyright:
- This material is "Alicia Hartlieb and Martin Hartlieb"'s paper: Based on "The Impact of Giga-Castings on Car Manufacturing and Aluminum Content".
- Paper Source: [No DOI URL provided in the text]
This material was summarized based on the above paper, and unauthorized use for commercial purposes is prohibited.
Copyright © 2025 CASTMAN. All rights reserved.