FEV develops innovative solutions for the car body production of the future

FEV, a leading development service provider in the field of sustainable mobility, is developing innovative solutions for the car body production of the future together with 18 international partners in the MeGiCast consortium project. The focus is on so-called gigacasting - the aluminum die casting of large structural components, which is considered a key technology for more efficient, lighter and more sustainable vehicles.

CGI model of a car body / FEV Group GmbH

Hybrid technology as the next stage of gigacasting

FEV is going beyond the current state of the art and researching highly integrated body designs with hybrid production technologies. This involves combining flat sheet metal components with cast reinforcements. The result: a front end consisting of just three components that is up to 18% lighter than a purely cast version. In addition to saving weight, the new solution also enables more efficient assembly and lower production costs.

Holistic approach: CO₂, lifecycle and economic efficiency

Within the project, the partners are analyzing a gigacasting front end concept in comparison to a modern multi-material approach. Technological aspects, CO₂ balances, economic efficiency and life cycle assessments (LCA) are being comprehensively evaluated.

“We are integrating more and more functions directly into the vehicle structure in order to streamline processes and achieve maximum efficiency,” says Christian Kürten, Managing Director at FEV Vehicle.

At the same time, Dr. Hagen Wegner, Director at FEV Consulting, emphasizes that despite all the innovation, a balanced relationship between design, costs and sustainability remains crucial.

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Looking to the future: gigacasting, gigastamping - or both?

Despite the great potential of gigacasting, FEV sees the future in a combination of different technologies: “Innovative processes such as gigastamping or hybrid approaches must be taken into account in the overall view of production,” says Kürten.

About FEV

FEV has been developing technological and strategic solutions for leading OEMs and players in the global mobility ecosystem for over 45 years. With over 7,000 employees at more than 45 locations worldwide, FEV is also driving innovation in the aviation, energy and software sectors - always with the aim of helping to shape a sustainable and intelligent future.