- 02/03/2026
- Report
- Lightweight trend
Die-cast aluminium wheels reduce weight and CO2 footprint
Albert Handtmann Metallgusswerk GmbH & Co. KG has further developed its die-casting processes to enable the production of complete aluminium wheels. The newly developed casting system allows, for the first time, the manufacture of complete aluminium wheels using high-pressure die casting (HPDC). The wheels celebrated their premiere at EUROGUSS 2026 in Nuremberg. Series production readiness is planned for the course of the same year.
Written by Editors EUROGUSS 365
The development was carried out entirely in-house – from the initial concept and the design of the casting system through to production. The wheel blanks are produced in series at Handtmann using the die-casting process. Subsequent processes such as machining, coating and all quality assurance steps are carried out by the partner company Cevher Group. Both partners have aligned the entire process to the requirements of the automotive industry.
“By introducing this technology, we are opening the automotive wheel segment to high-pressure die casting for the first time and, at the same time, laying the foundation to transfer this process to other components in the future. This allows us to set new standards in both the light-metal and automotive industries,” says Dirk Seckler, Co-CEO of Handtmann Leichtmetallguss.
HPDC as a key technology for structurally relevant aluminium components
At the core of the casting process is high-pressure die casting (HPDC), a technology proven for the production of large series. Handtmann is applying this high-performance die-casting process to the manufacture of complete aluminium wheels for the first time – a product segment that has so far been reserved exclusively for low-pressure die casting.
In HPDC, molten aluminium is injected into a precisely designed die at very high pressure and within a very short time, where it solidifies under applied pressure. This enables the production of complex, thin-walled components with high dimensional accuracy and very good surface quality in large volumes. As a result, the new light-performance wheels are up to 20 to 30 per cent lighter than conventional low-pressure die-cast wheels.
The combination of short filling times, high clamping forces and automated processes enables efficient series production. Components are produced close to net shape, reducing the need for machining. HPDC thus forms the basis for manufacturing structurally relevant aluminium components such as wheels in high-volume production.
New design freedom for OEMs
For vehicle manufacturers and wheel producers, reducing CO2 emissions is a key priority both in production and during vehicle operation. The new die-cast wheel contributes to this by lowering weight and enabling aerodynamically optimised geometries, which reduce air resistance and increase vehicle range – particularly in electric vehicles.
“Thanks to the enhanced design freedom offered by HPDC and the minimal distortion inherent in the die-casting process, we can realise wheel designs that were simply not feasible with conventional methods. This will appeal equally to designers and car enthusiasts. In addition, the often-required aerodynamic cover becomes unnecessary, further reducing weight and cost,” says Andreas Würzer, Head of Technical Development.
Benefits for end customers and fleet operators
End customers benefit from a light-performance wheel that noticeably improves handling due to reduced unsprung mass. The combination of design, driving dynamics and sustainable production has a positive effect on overall vehicle performance.
Fleet operators – for example in logistics, car sharing or corporate mobility – also benefit from efficiency gains and cost reductions. Lower energy or fuel consumption improves the CO2 footprint in operation and can be used for certification purposes and sustainability reporting.
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