Handtmann announces new light-alloy cast components
Automotive supplier Handtmann has announced the production of further components for vehicle manufacturing using the aluminium die-casting process. Following its successful launch in autumn 2024, the so-called ‘Megacasting’ process will be expanded at the Biberach site in Baden-Württemberg. As Dirk Seckler, Managing Director of Albert Handtmann Metallgusswerk GmbH & Co. KG, confirmed at the “Global Giga Casting” congress in Kassel, following the initial components for the battery sector, tailgates as well as front and rear subframes are now also being included in the planning.
“We expect significant changes in the supplier market as a result of the transformation in the automotive industry,” said Seckler. “Handtmann has decided to take on the role of innovation leader, which we will now be expanding.”
Megacasting is a production process that enables the manufacture of large and complex structural components in a single casting. For customers, the advantages of large-scale cast components include, above all, a high degree of functional integration and reduced manufacturing complexity – accompanied by lower procurement and logistics costs. This eliminates numerous production steps and avoids labour-intensive joining and finishing processes such as welding and bonding. Furthermore, the weight of the body is significantly reduced, which is particularly relevant for electric vehicles. With Megacasting, Handtmann significantly reduces production time in automotive manufacturing, substantially improves material efficiency and also enhances the structural integrity of vehicles.
On Thursday in Kassel, Handtmann provided an update on its expectations regarding market developments. According to the company’s calculations, the proportion of aluminium castings in vehicles will rise from the current 130.3 kg to 142.5 kg by 2030. The products themselves will also change.
Handtmann anticipates that housings for internal combustion engines and transmission components will become less relevant in terms of competition in future. Competitive pressure is expected to be particularly high for standard components such as electric motor housings, longitudinal beams and suspension strut domes, as there is already sufficient capacity for these components in the supplier market. According to the forecasts, the winners of this transformation will include EV components, structural parts and chassis components. For these components, development expertise and new technologies such as megacasting can provide a competitive edge. The Biberach-based company is seizing the opportunity to focus particularly on large and complex new products, thereby setting itself apart from the competition.
The Handtmann Group decided to invest in its first megacasting die-casting machine during the COVID-19 pandemic, investing a sum in the tens of millions. The process, which is in high demand in the USA and Asia, is still new in Europe. Handtmann is the first European supplier to use Megacasting in series production. By adopting this technology, the Group aims to strengthen its German production sites and support its European customers and business partners.
Megacasting – the new process and its application at Handtmann
The Handtmann Group
The Handtmann Group is a globally active technology company in the manufacturing sector with around 4,700 employees, 3,300 of whom are based at its headquarters in Biberach an der Riß in Germany. Cutting-edge technology, innovation and a people-centred approach are at the heart of this family-run company. The group is organised into six business divisions with autonomous management structures: light metal casting, systems engineering, filling and portioning systems, plant engineering, plastics technology and e-solutions. At the head of the group is a holding company acting as the management, financing and investment entity.
In 2023, Handtmann generated a turnover of 1.3 billion euros. Thanks to a consistent policy of retaining profits, the company’s owners are able to make substantial investments in research and development as well as in production facilities. In this way, the founding family provides long-term support for sustainable, high-quality growth.
The group is currently represented in over 100 countries with its own production facilities, branches and sales offices. Founded in 1873 as a small-scale brass foundry, the Handtmann Group celebrated its 150th anniversary in 2023.
Light Metal Casting Division
As part of the Group, the Light Metal Casting Division is a strategic partner for the development and manufacture of die-cast aluminium components for the automotive industry. Handtmann is the first European Tier 1 supplier to manufacture structural parts using the cutting-edge Megacasting innovation.
The subsidiary is the largest family-run light metal foundry in Europe, with sites in Germany, Slovakia and China.