Milestone: Bühler celebrates 50th order for its Megacasting solution

Strategic positioning with experience

Bühler identified the potential of megacasting early on, particularly against the backdrop of growing electromobility. With almost 100 years of experience in die casting and over 30 years of focusing on large-volume components, the company was well positioned to shape the technological change. Today, the Carat series includes solutions with clamping forces of up to 92,000 kilonewtons, suitable for classic and electric vehicle architectures.

Technological progress for structural components

Megacasting enables the production of one-piece components such as front and rear undercarriages or battery housings, replacing 50 to 100 individual elements. The advantages: lower weight, fewer joining processes, reduced material losses and overall more sustainable production. With the Carat 560, 610, 840 and 920, Bühler offers suitable systems for different requirements.

Global customer base and comprehensive support

Users of Carat megacasting solutions include companies such as Volvo, Honda, Duoli Technology, Albert Handtmann Metallgusswerk and GF Casting Solutions - with plants in Europe, Asia and North America. Bühler supports the entry into megacasting with comprehensive support: from component development and training to process optimization.

“We work closely with our customers to ensure a successful start to megacasting,” says Martin Lagler, Director Global Application Technology Die Casting.

Focus on availability and service life

In order to meet the requirements for productivity, quality and sustainability, Bühler relies on durable machines with high availability and low reject rates.

“Many of our die casting machines have been in use for over 20 years - proof of their quality,” emphasizes Michael Cinelli, Director Product Management Die Casting.

Existing systems can be upgraded to current performance levels, which reduces operating costs and environmental impact.

Presence in all key regions

With production and service locations in Europe, China and the USA, Bühler offers local proximity and global standards.

“We are present in all key automotive markets, speak the language of our customers and understand their culture,” says Cornel Mendler, Managing Director Die Casting.

The three regional centers coordinate production, project implementation and spare parts supply.

Future investments in megacasting

With almost 1,000 Carat systems installed worldwide, Bühler is underlining its claim to help shape the transformation of automotive manufacturing.

“Megacasting is driving fundamental change in the industry, and we continue to invest in technologies, expertise and partnerships that make our customers successful,” says Mendler.