From cars to space: the opportunities that space travel offers die casting

Cost pressure as a catalyst

The trend towards greater cost-effectiveness could pave the way for die casting: "In aerospace, the principle of economic functionality increasingly applies," says Requena. This means that it is not about maximum perfection, but about the best possible combination of weight, function and cost. This is precisely where die casting can score points - especially for less stressed structural elements, brackets or geometries with a high degree of complexity.

A property that has already been described as problematic here could suddenly become an advantage: porosity. What is considered a disadvantage in aviation could prove useful in space travel. "Many satellites have to burn up in a controlled manner on re-entry into the earth's atmosphere. Porous materials have the advantage that they dissolve more quickly at high temperatures," explains the DLR expert. The magic word is “demisability”. This means that the very structure that previously disqualified die casting as safety-critical could be welcome as a material quality in certain space applications.

Certification as a surmountable hurdle

Of course, aerospace is also a regulated market. Components, even if they are not safety-relevant, are subject to norms and quality standards. However, in contrast to manned aviation, these requirements can be kept manageable depending on the application. Materials scientist Requena emphasizes: “If you want to use die casting specifically in non-hazardous areas, you can certainly find ways to manage the certification effort.”

For the industry, this means that getting started involves effort, but is feasible - especially for foundries that are prepared to accept new requirements, documentation and processes. Specializing in specific component groups or functional modules could make it easier to enter the market.

Hybrid approaches

Another way to meet space requirements could be hybrid manufacturing processes. Processes such as laser metal deposition (LMD) offer opportunities to apply additional layers to existing geometries - for example to reinforce, expand functions or integrate technical interfaces. “Satellite construction in particular often results in complex assemblies with different requirements,” explains Requena. Such hybrid approaches could not only open up new markets, but also expand the technological profile of foundries that want to position themselves for the future.

Outlook: From supplier to co-designer

The proportion of die-cast components in the aerospace industry is still negligible. However, the dynamics in the “new space” segment, coupled with the increasing demand for cost-efficient production technologies, could change this. For foundries that are currently suffering from the slump in the automotive industry, this may open up an opportunity for diversification.
Space cannot be a substitute for the automotive sector, but it is a promising additional field. Die casting could experience an upswing, particularly in the area of small satellites - as a cost-efficient, adaptable and accepted technology. The prerequisites are: technical adaptability, process knowledge and staying power. Those who are prepared to take the plunge can make the leap from cars to space.