Megacasting from the perspective of a designer

Discover how Megacasting is revolutionizing automotive manufacturing by replacing complex assemblies of 70-100 parts with single cast components (depending on the complexity of the basis). Using massive 6,000+-ton machines, companies like Handtmann are transforming vehicle production through this breakthrough technology. Learn how this innovation challenges traditional design approaches, requires specialized team structures, and promises to reshape the future of car manufacturing through simplified assembly and improved performance.

man in orange turtleneck sweater holds presentation — Stefan Kneer, Head of Design and Business Development, Albert Handtmann Metallgusswerk GmbH Co KG

From 70-100 Parts to One: The Megacasting Revolution in Car Manufacturing

Introduction

In the world of automotive manufacturing, revolutionary technology is changing how cars are built. Megacasting, a process that can replace multiple individual parts with a single cast component, represents one of the most significant advances in vehicle production in recent decades. This transformation is being led by companies like Handtmann, a 150-year-old manufacturer that has embraced this innovative approach to car manufacturing.

The Evolution of Auto Manufacturing: Handtmann's Journey to Innovation

Handtmann's story exemplifies the transformation taking place in automotive manufacturing. Founded 150 years ago and now in its fifth generation of family leadership, the company has grown to employ 4,300 people worldwide. With operations spanning six business divisions across automotive and food sectors, Handtmann generates approximately two-thirds of its €1.2 billion revenue from automotive operations.

The company's global footprint includes five key manufacturing locations: their headquarters and technology center in Biberach, Southern Germany; a facility in Eastern Germany (Annaberg); two plants in Slovakia; and one in China. This network operates 99 casting machines, with their newest addition being a 6,100-ton Megacasting machine.

Traditional automotive manufacturing typically involves assembling a wide variety of individual parts through welding and joining processes. This approach, while proven, requires complex supply chains, multiple assembly steps, and significant quality control measures at each stage. Megacasting represents a complete departure from this conventional method.

Breaking Down Megacasting: A Manufacturing Revolution

Megacasting begins with machines typically in the 6,000-ton class. These massive machines weigh approximately 400 tons, with additional tooling that can reach 1200 tons. The scale of this equipment requires specialized infrastructure and facilities to operate effectively.

The primary applications for Megacasting include:

Front and rear vehicle bodies
Battery frames for electric vehicles
The benefits of Megacasting are transformative. By replacing complex assemblies of 150 or more parts with a single cast component, manufacturers can achieve significant weight reduction, dramatic part count reduction, and substantial cost savings. This simplification of the manufacturing process also reduces potential points of failure and assembly complexity.

Engineering the Impossible: Technical Challenges and Solutions

Developing Megacast components requires a complete reimagining of the design process. As demonstrated by real-world examples, engineers cannot simply take an existing welded assembly and convert it directly into a casting. The traditional approach of having multiple of individual components - each with their own specific requirements, functions, and performance metrics - must be completely reconceptualized. The redesign process must specifically account for the unique constraints of die casting, including wall thickness limitations and manufacturing feasibility.

The development begins with sophisticated topology optimization, where engineers input comprehensive load models and define preliminary tool separation points. The optimization process reveals critical load paths that emerge during crash scenarios and other stress conditions. These load paths then serve as the foundation for translating the abstract optimization results into practical CAD geometry, all while adhering to manufacturing constraints like draft angles and wall thickness requirements.

The technical process involves several stages of simulation and validation:

Initial topology optimization based on load models
Design adaptation for manufacturing constraints
Crash and NVH analysis
Flow simulation for material distribution
Cooling and solidification modeling
Tool design and maintenance planning

Material considerations present unique challenges in Megacasting that go beyond traditional casting processes. One of the most significant challenges is achieving consistent material properties across these massive components. As explained by Handtmann's engineers, when dealing with large castings, the pressure effect diminishes significantly in areas far from the injection point - no matter how much pressure is applied, it simply doesn't reach the final solidification zones effectively. This requires innovative solutions in both tool technology and ventilation systems to achieve acceptable material properties.

Additionally, engineers must accept and design for the reality that material properties will vary across different sections of the component. The focus shifts to ensuring optimal material characteristics in critical load-bearing areas while managing acceptable variations in less crucial zones. This requires extensive simulation work and cooling system optimization to direct the best material properties to where they're most needed for structural integrity.

Building the Future: Teams and Technology Working Together

The complexity of Megacasting has fundamentally transformed the required skill sets and team structures in manufacturing. The traditional model of having a single engineer handle an entire component's development is no longer viable. As Handtmann has discovered, the scale and complexity of Megacasting demands a highly specialized, collaborative approach.

A modern Megacasting development team typically includes:

Two functional part designers, with one often serving as the project coordinator
A dedicated flow system designer focusing on gating and runner systems
A tool concept specialist who also handles simulation work
Multiple simulation experts covering various analyses (crash, NVH, modal analysis, lifetime analysis)

Beyond technical skills, team members must develop enhanced soft skills in project coordination and communication. The iterative nature of Megacasting development requires constant collaboration, as changes in one area (such as package modifications or simulation results) trigger cascading effects that impact multiple aspects of the design. This simultaneous engineering process runs from early development through to tool kick-off, requiring seamless coordination among all team members.

The future of automotive manufacturing will increasingly rely on this collaborative approach. Teams must combine expertise in traditional engineering, materials science, simulation technology, and manufacturing processes. This integration of skills and knowledge is essential for successfully implementing Megacasting technology.

Conclusion

Megacasting represents more than just a new manufacturing process - it's a fundamental shift in how vehicles are built. As companies like Handtmann continue to develop and refine this technology, we can expect to see broader adoption across the automotive industry. The promise of simplified assembly, reduced costs, and improved vehicle performance makes Megacasting a crucial technology for the future of automotive manufacturing.