Beyond gearbox housings and cylinder heads – new sales channels for die casting

Diversification as a challenge

Trade associations and consultants have been preaching it for years, but implementation remains difficult. Although aluminium, magnesium and zinc die casting processes can in principle be used across all industries, markets such as aviation, medical technology and defence follow different rules: quantities are smaller, development cycles are longer and certification requirements are significantly higher.

Anyone who wants to supply the aviation industry needs ISO 9001 certification, for example, and for some parts even EN 9100 certification. ISO 13485 applies to medical technology, and in safety-critical areas, process documentation, traceability and non-destructive testing methods are mandatory. There are also economic hurdles: small series require flexible tools, quickly convertible machines and calculations that work even for 500 parts instead of 50,000.

But what does diversification look like in practice? Some foundries have taken the plunge. A look at selected companies in Europe shows where the journey can take us.

Successful examples from Europe

The Schüle Group from Schwäbisch Gmünd, with around 750 employees at locations in Germany, Poland and Slovakia, is one of the traditional automotive suppliers. Schüle is now pursuing a targeted diversification strategy – and is also manufacturing components for medical technology for the first time. It produces cylinders and cylinder heads for dental compressors from renowned German manufacturers, cast using the aluminium cold chamber process and then CNC-machined. With its expansion into medical technology, building technology and leisure products, Schüle is demonstrating how established foundries can tap into new markets with precision, process reliability and materials expertise.

Schött Druckguss GmbH in Menden is also active in the field of medical technology. The company manufactures aluminium die-cast parts for laboratory, diagnostic and rehabilitation technology – such as housings for analysis devices, pump modules and components for dental units. The requirements for dimensional accuracy, cleanliness and corrosion resistance are particularly high here.

Kalmbach GmbH, based in Velbert, is one of Germany's long-established zinc and aluminium die-casting foundries. In addition to automotive customers, the family-owned company supplies manufacturers in the electrical and control engineering sectors with housings, connectors and precision components. Production takes place in hot-chamber systems. The castings are then CNC-machined and electroplated.

Protocast GmbH in Wuppertal pursues a similar course. The company manufactures aluminium, zinc and magnesium die-cast parts for electronics, lighting and medical technology. Its portfolio includes precision housings for power electronics, LED modules and sensor components.

The Danish company ScanCastor demonstrates how design and function can be combined. The company specialises in castors, fittings and design components for the furniture industry. Several million moulded parts are produced annually from die-cast aluminium, zinc and magnesium, which are then chrome-plated, powder-coated or anodised. The castings combine load-bearing capacity with an attractive surface finish – a combination that is increasingly in demand in the consumer goods industry.

HDO Druckguß- und Oberflächentechnik GmbH from Paderborn stands for decorative and functional aluminium die-cast parts in household and building technology. The spectrum ranges from fitting housings and design fronts for household appliances to structural elements for smart home systems. Production is carried out using the cold chamber process, supplemented by the company's own painting and electroplating facility.

Another example is provided by Italian company MAG Bike AG in Bozen. Using a patented process, the company develops and produces one-piece e-bike frames made of cast magnesium, with battery compartments and cable channels already integrated into the casting. MAG Bike thus demonstrates that light metal casting also has potential in the lifestyle segment.

The Turkish company Kalkanci Aluminium Die Casting, based in Istanbul, demonstrates that it is possible to establish oneself in the aerospace industry with die-cast products. Its product range includes complex aluminium components for these industries. Typical products are housings and structural components for avionics and engine systems. Tests using CT scanners and spectrometers ensure the required component quality.

Thinking outside the box

Not all markets are equally accessible. Industries such as defence and drone manufacturing remain difficult for many foundries – for political as well as technological reasons.

On the one hand, export restrictions, safety certifications and lengthy procurement processes make market entry difficult. On the other hand, military applications place extreme demands on materials and processes: high strength, thermal shock resistance and low-vibration structures. Classic automotive alloys reach their limits here.

The defence sector also demands uncompromising quality assurance. Gas and air inclusions are not tolerated in safety-relevant components. Vacuum die casting, thixocasting and semi-solid processes are considered the preferred technologies, supplemented by CT and ultrasonic testing with full traceability. The production logic also differs significantly from the automotive business: while millions of components are manufactured there every year, the quantities in the defence sector are often only in the three-digit range. The business is particularly attractive for specialised foundries that have mastered small series, prototyping and high precision.

Dynacast, a global precision die casting manufacturer with locations in Europe, is an example of technological connectivity. The company supplies die cast parts for industries such as electronics, telecommunications and industrial control technology, as well as components for lightweight drone systems, which are also used in the defence sector.

From parts manufacturer to development partner

For many foundries, dependence on the automotive industry remains a structural risk. However, examples show that new markets can be tapped into when technological excellence and industry-specific expertise come together.

Those who obtain certifications such as EN 9100 or ISO 13485, master small series processes and are prepared to embrace new requirements can also successfully position die casting in medical technology, electronics or lifestyle. The transition from a pure parts manufacturer to a development partner who combines material expertise, design know-how and process stability is helpful.

Diversification requires investment, patience and specialisation. But it shows that die casting can do more than just gearbox housings and cylinder heads.