Aerodynamics also benefit from the greater design freedom. Wheel rotation and the interaction between the wheel, tyre and wheel arch create turbulence that affects aerodynamic drag. By integrating aerodynamic functions directly into the wheel geometry, separate aerodynamic wheel covers can be eliminated, for example. This saves additional components and assembly steps. The benefit therefore lies in the combination of lower weight, improved aerodynamics and functional integration.
From innovation to economically viable high-volume production
Technical performance alone is not enough to ensure market success. A wheel must also be manufactured with reasonable production effort, consistent quality and competitive costs. High-pressure die casting offers considerable potential here: compared with conventional low-pressure die casting, cycle times can be reduced by a factor of two to three. A high degree of automation, smaller machining allowances and the potential elimination of a separate heat treatment process reduce manufacturing effort.
Handtmann is cooperating with the Turkish Cevher Group on industrialization. While Handtmann develops the casting system and produces the wheel castings, its partner handles subsequent machining and finishing. Technical validation has been completed. The partners are now working together to translate the technological advantages into an economically viable high-volume production solution.
New functions, new business areas
Handtmann is already looking beyond the existing solution for its high-voltage battery frame. The focus is increasingly shifting towards a systems approach: the battery frame is to evolve from a purely structural component into an integrated system carrier. To achieve this, the company is challenging conventional component boundaries and examining which additional functions can be integrated directly into the aluminum casting.
The aim is to create customized solutions that combine several functions in a single component, reduce the number of additional parts and interfaces, and thereby lower weight, assembly effort and complexity. In the future, this could enable battery frames, as well as other innovative structural component concepts, to make an even greater contribution to simplified vehicle architectures.
Such developments are also changing the way suppliers work with their customers. Rather than simply manufacturing to predefined specifications, suppliers are increasingly contributing their expertise at an earlier stage of product development. Bringing together different areas of expertise and taking a holistic approach can shorten time-to-market while creating opportunities to advance proprietary technologies, develop customized solutions and enter new business areas. Handtmann sees potential in robotics and stationary energy storage systems, for example.
Digitalization is also becoming increasingly important. Data-driven pattern recognition makes it possible to identify anomalies in production processes at an early stage and pinpoint potential causes of errors more quickly. Practical applications have already demonstrated that this can significantly shorten response times and enable more targeted process optimization.
From manufacturing partner to innovation driver
This raises a fundamental question for the European die-casting industry: what role do companies want to play in the value chain in the future? The ability to manufacture high-quality components economically and in large volumes will remain essential. However, in international competition, the ability to help shape technological developments, identify market needs at an early stage and bring proprietary solutions to series production will become increasingly important.
For Handtmann, this means strategically combining the three pillars of Built to Print, Built to Specification and Innovation. Built to Print safeguards existing business and provides a solid economic foundation. But Built to Print alone is no longer enough. Customer requirements are changing, and with them the role of the foundry.
Growth comes from developing new solutions together with customers. This is why Built to Specification is becoming increasingly important. It strengthens collaboration with customers from the early stages of development.
Proprietary innovations, in turn, make it possible to develop new product groups and bring components into aluminum die casting that were previously manufactured from other materials or using different processes. What matters is not simply which technologies a die caster has mastered, but how quickly that expertise can be translated into tangible customer benefits.
The strategies required to achieve this and the opportunities emerging in new markets will be discussed by industry decision-makers at the EUROGUSS Executive Circle in Frankfurt on 20 and 21 January 2027. Handtmann is supporting the event as a Leadership Partner. Dirk Seckler will take part in the panel discussion “Europe in the Global HPDC Game: How to Win the Race”.
