Handtmann expands light metal casting portfolio: new components for vehicle production

Automotive supplier Handtmann is continuing to drive forward the use of aluminum die casting and is planning to produce additional vehicle components using the megacasting process. Following the successful launch in fall 2024 at the Biberach site (Baden-Württemberg), the process is now being expanded. As Dirk Seckler, Managing Director of Albert Handtmann Metallgusswerk GmbH & Co. KG, confirmed at the Global Giga Casting Congress in Kassel, in addition to the components for the battery area that have already been launched, tailgates as well as front and rear end components will also be produced in future.

Handtmann focuses on innovation in megacasting

“We are expecting major changes in the supplier market as a result of the transformation in the automotive industry,” said Dirk Seckler. “Handtmann has decided to take on the role of innovation leader, which we will now expand.”

Megacasting enables the production of large and complex structural components in a single casting. This process significantly reduces the number of production steps and eliminates labor-intensive processes such as welding and gluing. Customers benefit from a high level of functional integration, lower production and logistics costs and improved material efficiency. Reduced body weight plays a key role in electric vehicles in particular.

By using megacasting, Handtmann significantly shortens production times and at the same time increases the structural integrity of vehicles.

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Growth potential in aluminum casting

At the congress in Kassel, Handtmann presented current forecasts on the development of the aluminum casting market. According to company calculations, the proportion of cast aluminum in vehicles will increase from the current 130.3 kg to 142.5 kg in 2030. At the same time, the requirements for components will change.

Handtmann expects classic combustion engine and transmission housings to become less important. Standard components such as electric motor housings, side members and suspension strut domes are already subject to strong competition, as there is sufficient capacity on the market. However, the company sees growth potential in EV components, structural and chassis components. Handtmann aims to set itself apart from the competition here through targeted development and the use of innovative technologies such as megacasting.

Megacasting as a strategic investment

Handtmann decided to invest in the first megacasting die casting machine during the coronavirus pandemic, spending tens of millions of euros in the process. While the process is already widely used in the USA and Asia, Europe is still at the beginning of this development. Handtmann is the first European supplier to transfer megacasting to series production..

With this strategy, the company is not only strengthening its production facilities in Germany, but also securing its competitiveness on the European market.