Megacasting from a Designer’s Perspective

Megacasting is one of the most innovative developments in the foundry industry in recent years. This process, in which large structural components are produced from aluminium using the die casting method, is gaining increasing importance worldwide. But what does this development mean from a designer’s perspective? An article by Stefan Kneer, Head of Engineering and Business Development at Albert Handtmann.

Man with orange tie and woman with blue scarf smile while looking at a piece of metal

OEMs that rely on megacasting aim to replace complex assemblies made up of numerous individual parts with a single component. This not only reduces weight and cost but also simplifies production processes. The rear underbody, in particular, has become a standard application for megacasting. Battery frames produced as single castings are also gaining significance. Replacing multiple assemblies with one large casting considerably reduces production costs. In addition, the advantages of the die casting process allow for highly complex geometries and functional integration within a single part.

Component manufactured using the megacasting process

Challenges in Developing Megacasting Components

The development of megacasting components brings with it a wide range of new challenges. Designing these parts requires not only the integration of various requirements and functions of conventional assemblies but also a precise consideration of the specific conditions of the die casting process.

Since megacasting components are entirely new products with no predecessors, there are no empirical values to draw upon. Designers must therefore create a new specification sheet, which forms the basis for simulation models. These models cover a wide range of load cases, including operational loads, rear and side crash scenarios, as well as NVH (Noise, Vibration and Harshness).

Particular attention is paid to integrating the different functions and requirements of the original assembly into a single part. These requirements include mechanical properties, interfaces with adjacent components, and specific manufacturing constraints.

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Topology Optimisation and Subdivision Modelling Enable Intuitive Creation of Complex Forms

The foundation of a designer’s work lies in simulating the optimal topology based on product load cases and the available installation space. This is an essential step to ensure that material is only used where it is needed. In the subsequent derivation of CAD data, Handtmann has been successfully using subdivision modelling for several years – a technique originating from computer graphics and the film industry, which significantly simplifies geometry creation and optimisation.

Subdivision modelling enables designers to create complex shapes intuitively and efficiently. This is particularly important for megacasting components, where the optimal geometry plays a crucial role in structural integrity and manufacturability. The method also allows for quick adaptation to changing requirements, increasing flexibility throughout the development process. As a result, development times are shortened, and significant weight reductions can be achieved.

Another key element in the development of megacasting components is Design for Manufacturing (DfM). Functional and casting-related requirements must be considered simultaneously and iteratively from the early stages of development. Parallel simulation loops play a decisive role in ensuring the manufacturability of the component.

Casting simulations help identify potential issues such as air entrapment, material defects or insufficient die filling. This information is then incorporated into geometry optimisation, resulting in a final product that meets the high quality and safety standards of the automotive industry.

The Expanded Role of the Designer

The complexity of megacasting components has fundamentally changed the designer’s role. Whereas in the past a single designer could take full responsibility for a part, this is no longer feasible today.

Development now requires collaboration among at least four designers: two focus on part geometry, one designs the gating and runner system, and another is responsible for the die casting design. This teamwork is supported by a structured model architecture and targeted simulation models.

In addition to collaboration, continuous professional development plays a crucial role. Designers must constantly expand their knowledge of new technologies and methods to meet rising demands. This includes not only technical expertise but also organisational and communication skills to coordinate collaboration across different departments.

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New Requirements for Tools and Materials

The larger parts involved in megacasting also pose new challenges for tooling and materials. New vacuum, slider and die temperature control concepts must be developed. The long flow paths of the molten aluminium allow for only limited intensification pressure, requiring innovative process approaches. Furthermore, dies must be designed for ease of maintenance to minimise downtime.

Material selection is another critical factor. Aluminium alloys suitable for megacasting must offer high strength and good castability while also meeting requirements for corrosion resistance and recyclability. Designers are therefore challenged to align material properties precisely with part geometry and to find optimal solutions balancing flow behaviour, tolerances and strength.

Efficiency Gains Through Megacasting

Despite its complexity, the development of megacasting components is overall a highly efficient process. Instead of developing, producing and storing numerous individual parts, all processes focus on a single component. This not only reduces production effort but also simplifies administrative processes for OEMs.

Another key advantage is the reduction in development time. By employing modern methods and optimised manufacturing processes, the time span from the initial concept to series production can be significantly shortened. This provides OEMs with a decisive competitive edge, particularly in a market characterised by rapid innovation cycles.

Conclusion

Megacasting presents designers with a wide range of new challenges but also enormous opportunities for the automotive industry. Through innovative approaches such as topology optimisation, subdivision modelling and close interdisciplinary collaboration, these challenges can be successfully overcome. The efficiency gains resulting from the substitution of complex assemblies make megacasting a forward-looking technology with great potential. Moreover, megacasting contributes to sustainability by optimising material usage and improving recyclability. The industry is thus facing an exciting transformation that is fundamentally redefining the role of the designer.

With this investment, Handtmann demonstrates its entrepreneurial spirit and commitment to innovation. Megacasting is a key element of Handtmann’s strategy to support its customers through transformation and strengthen the competitiveness of the German automotive industry. Investments in new processes and technologies are the key to ensuring long-term growth, innovation and competitiveness.

Through megacasting, Handtmann is successfully entering new product segments. In line with the company’s guiding principle “Ideas for the Future,” Handtmann will continue to enhance its competitiveness and position itself as a reliable die caster and development partner with over 150 years of experience.