“The machine must fit the component”: Not all roads lead to giga-casting

Their guest: Professor Martin Fehlbier, head of the Foundry Institute at the University of Kassel and organiser of the first International Giga Casting Conference. What followed was not a celebration of the biggest machines, but a thoughtful discussion about what’s possible, what’s needed, and what might be getting overlooked in the current hype cycle.

“I think it’s a dramatic change for production,” said Fehlbier. “Now we can have methods to save hundreds of parts in only one single casting. But it’s not a self-running process. You have to really think about what makes sense – for your part, your setup, your goals.”

Bigger isn’t always better

Asia is charging ahead. Chinese OEMs are installing 8,000–9,000 ton machines at breakneck speed. Tesla is already far down the road. In contrast, European manufacturers are taking a more deliberate path – and that might not be a bad thing.
“Volkswagen, for instance, says: use the right-sized machine for the right-sized part,” Fehlbier explained. “4,800 to 6,000 tons might be completely sufficient. And you can join large parts too – you don’t have to cast everything at once.”

For Niklas and Zetterström, the discussion around giga casting has become too narrow. “Everyone’s talking about machine size,” Zetterström said. “But no one’s really talking about productivity, or what these machines actually deliver in real production environments.” Niklas added: “It’s not about the biggest machine – it’s about the entire process. What’s the output? What’s the real benefit?”

Alternatives with real potential

Rheo- and thixocasting don’t often make headlines, but they were a focal point in the podcast. For the hosts, these technologies offer a realistic and perhaps underappreciated alternative.

“Rheocasting is a very good alternative for the future,” said Fehlbier. “You might be able to produce the same part on 30 to 40 percent smaller machines. That saves costs, reduces wear, and lowers melt temperature and filling speed. But you need to learn a lot at the beginning.”

Niklas warned that testing such processes with standard tools can lead to wrong conclusions:  “If you don’t adapt the tool to the technology, it doesn’t work. But that’s not the fault of the process – it just wasn’t set up right.” For small and mid-sized foundries with limited investment budgets, these processes could offer a more accessible route into advanced casting – without the need for massive new machines.

 Material intelligence and process insight

New Materials were another key theme. Fehlbier advocates for simplicity over variety:
“We don’t need thousands of alloys. One or two would be best for a foundry.” But process control still lags behind. “The material behaviour in the die is still a black box for many,” Fehlbier said. “We need more sensors, more understanding of how flow length and oxide formation affect casting quality.”

Artificial intelligence could help – but only if the systems can support it. “Right now, less than 10 percent of the machines can handle AI topics,” Fehlbier noted. “We’re working on that, with partners like Bühler, to build the foundation.” Niklas sees potential: “If everything starts digital, you don’t have to retrofit legacy systems. That’s a real opportunity.”

A space for discussion – not just size

The Giga Casting Conference in Kassel was a success by the numbers: 419 participants from 25 countries, over 200 companies, a clear sense of momentum. But Goldcasting offered a timely reminder: the future of die casting will not be decided by machine size alone.  “We’re on a good path,” said Fehlbier. “We need to become cheaper – and better. And I think we can.”

What the discussion shows is that not only large machines are needed, but also great openness. Not every component has to be cast in the same way as at Tesla - sometimes a well-planned tool with a different process is enough. The future of die casting is not one-dimensional. It is modular, networked - and above all open to discussion.

Listen to the full episode!