From 123 to 1: Gigacasting at VW through the use of innovative three-plate tooling

Volkswagen is making a technological leap forward: key components for the new Electric Urban Car Family are being manufactured using large-scale casting at the Group's own competence centre in Kassel. Jörg Fenstermann, plant manager at the Volkswagen Group Components site in Kassel, gave EUROGUSS 365 an insight into the Group's large-scale casting strategy.

Three large aluminum die-cast parts displayed on white pedestals in front of a dark wall with graphic elements and text. The components have complex shapes — VW is breaking new ground with the cast parts for the Electric Urban Car Family, such as the battery frame (centre).

Person wearing a dark blue suit with a white shirt against a neutral gray background, formal business attire. — Jörg Fenstermann, plant manager at Volkswagen in Kassel since 2021

Mr Fenstermann, what specific role does the large-scale casting process play in the new battery systems for the Electric Urban Car Family? What components are produced using this process?

Jörg Fenstermann: The large-scale casting process – or gigacasting – plays a central role in the development of the new battery systems for the Electric Urban Car Family. One key component produced using this process is the battery frame. What used to consist of 123 individual parts is now realised in a single, highly integrated large casting. This not only reduces complexity, but also drastically reduces the number of logistics and joining processes. Thanks to our many years of experience in the field of die casting structural components, this development marks a significant advance and sets new standards in component manufacturing.

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What special technological features or innovations are you using?

Jörg Fenstermann: In order to meet the high requirements for structure, safety and efficiency, we are using an innovative 3-plate tool for the first time to manufacture the large casting. This technology enables us to halve the flow lengths of the aluminium in the casting process while achieving even greater component integration. The result is a particularly dimensionally stable, robust, and lightweight structural component – ideal for the requirements of modern electric vehicles.

Battery technologies are constantly evolving. How are you adapting foundry processes to provide future generations of batteries with suitable structures?

Jörg Fenstermann: The die casting process offers enormous flexibility thanks to the high degree of geometric freedom of the moulds. This means that we can implement both minor mould adjustments and completely new developments quickly and efficiently. This enables us to respond to technological advances in batteries at any time and provide the appropriate structural components. Even for future generations.

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You are pursuing an ambitious sustainability strategy. To what extent is this reflected in your battery components? Do you also use recycled materials?

Jörg Fenstermann: Sustainability is an integral part of our corporate strategy, and this also applies to the battery frames for future models such as the Volkswagen ID. Polo, Cupra Raval and Škoda Epiq. We consistently use recycled materials and employ a closed-loop process for the production of our aluminium die-cast parts. This not only reduces our carbon footprint but also conserves valuable resources.

BMW uses high proportions of secondary aluminium in the new iX3 even for dynamically loaded components such as rear axle carriers and wheels. Are there any similar efforts at VW?

Jörg Fenstermann: The Volkswagen Group's environmental goals are clearly defined, and we are doing our part to achieve them. We are pursuing a clear strategy of using die-cast aluminium alloys with high proportions of secondary aluminium. Our goal is to increasingly manufacture structural components made from recycled materials that are not only statically but also dynamically loaded, without compromising on quality or safety.

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Large aluminum die-cast component with a rectangular frame and three horizontal crossbars, displayed on a white pedestal in front of a dark wall with graphic elements and a blue background.

Cast from a single mould

A key highlight of Volkswagen's new MEB+ platform is the battery frame – the most complex casting in the entire Group to date. Instead of 123 individual parts, it will consist of a single large casting in future. Measuring 1.7 metres high and 1.15 metres wide, it marks a technological leap forward for VW.

The frame is manufactured using a three-plate tool, which enables shorter flow paths and thus increases process stability. The result: ten percent less weight per part and around 15 percent lower costs. The battery frame will be used in upcoming models such as the Volkswagen ID. Polo, the Cupra Raval and the Škoda Epiq.