Technological Restart in the Casting Industry

An examination of current production practices identifies three key areas for action for German light-metal foundries:

• Energy losses: Overall process energy efficiency stands at only 6.25 per cent. This massive inefficiency not only drives operating costs but also poses a serious business risk in times of volatile energy markets. An analysis by Prof. Sebastian Müller, Chair of Foundry Technology at Friedrich-Alexander University Erlangen-Nuremberg, together with Stone’s calculations, shows that in 2019 alone, the industry could have saved up to € 500 million in electricity costs – if all casting processes had been powered entirely by electricity.
• Material waste: Material consumption is up to twice as high as actually required for end-product manufacture. Complex gating and runner systems typical of traditional casting lead to significant scrap, recycling effort and unnecessary costs – directly reducing profitability.
• CO₂ emissions: The ecological footprint is alarming. German light-metal foundries emit around 1.22 million tonnes of CO₂ equivalents each year. This figure is not only environmentally problematic but, in view of stricter regulations and growing sustainability expectations from customers and investors, an increasing burden.

 
The industry therefore faces both economic and ecological challenges. Incremental optimisation will not suffice; what is needed is a disruptive solution.

A concept such as MAXImolding opens up new possibilities for stable processes, improved part quality and lower material usage. The difference compared with traditional methods can be summarised as follows:

New Properties, New Fields of Application

The technological shift from pouring an overheated liquid melt to processing a precisely tempered, semi-crystalline slurry forms the basis for measurable benefits that go far beyond cost savings.
Processing in a semi-solid state produces a spherical, non-dendritic microstructure, resulting in improved mechanical properties and higher component quality compared with conventional high-pressure die casting (HPDC). This opens new fields of application for cast parts – for example, safety-relevant or highly stressed components.
 

Energy and Cost Reduction through Efficient Processes

Lower process temperatures, shorter routes and demand-oriented energy input enable significant savings. MAXImolding reports potential energy reductions of 85–90 per cent, achieved through:

• Lower processing temperatures: magnesium alloys such as AZ91D processed at 480 – 580 °C instead of 600 – 680 °C.
• Elimination of losses: removal of central furnaces, melt transport and holding processes cuts major losses by up to 60 per cent compared with traditional casting.
• On-demand generation: energy is used only when a part is produced; heat is introduced directly at the machine from ambient to semi-solid temperature precisely and slowly.
• Efficient material use: new injection techniques allow almost loss-free processing; material consumption can fall by up to 50 %, reducing costs for recycling, raw material and reworking.
• Contribution to sustainability: using renewable energy for reactor heating enables almost emission-free operation, supporting brand value and long-term licence to operate under tightening regulation.
  These advantages not only challenge conventional processes but position semi-solid casting as a lean alternative to capital-intensive mega-press projects such as the Giga Press concept.

Flexible Instead of Gigantic

While giga-presses rely on scale and capital strength, a counter-movement is emerging: smaller, scalable and modular systems that integrate into existing structures. This approach combines energy efficiency with agility – creating new opportunities for small and medium-sized foundries.

Shorter paths, lower clamping forces and a lean layout make such processes not only more economical but also more adaptable in a constantly changing market.
 

Stricter sustainability regulations and CO₂-reduction targets act as additional drivers promoting the adoption of energy-efficient casting processes.

As-a-Service as a Success Model

Concepts such as SSM Reactor as a Service show that technological innovation in light-metal foundries need not entail high investment risk. The model transfers principles from IT and production digitalisation to the casting process: use instead of ownership. Companies benefit from predictable costs, continuous updates and technical expertise – without tying up capital.

At the heart of this approach lie four interlinked value propositions: component quality that opens up new markets and demanding applications; time and efficiency gains through a significantly simplified process and a service-based operating model; energy savings of up to 90 per cent that create a stable cost base and make production more resilient; and a future-proof technology that meets environmental goals, improves working conditions and strengthens long-term competitiveness.