Foundry Expert turned into Business Developer
My name is Fabian Niklas. I’m a passionate material engineer who found his calling in the dynamic world of foundries. I am on a quest to bring foundries into new markets and profitable casting ventures.
I founded Casting-Campus GmbH in 2022. It is a consultancy committed to blending technologies like high-pressure die-casting (HPDC) and Rheocasting with overall developments in the automotive industry, sustainability movements, and online marketing tools to fill the empty and/or unprofitable DCMs.
As a material engineer turned foundry expert, my core expertise lies in implementing and optimising casting processes, innovative part design, and strategic marketing. My journey has been fueled by a dedication to helping foundries thrive in an ever-evolving industry landscape.
At Casting-Campus GmbH, we go beyond traditional consulting. Our premium services cover positioning market development, sales support, feasibility checks, internal process reviews, and part development. We don’t just consult; we guide foundries from concept to casting. All these solutions come in packages, just like your Netflix subscription. So, no matter how many you call us, the project costs will stay the same.
I invite you to join our journey towards transformative foundry practices. Enjoy the presentations and detailed case studies below. Sign up for my newsletter Casting Insights and the Goldcasting Podcast to stay updated on industry insights, innovative practices, and the latest from Casting-Campus GmbH. You can also schedule a free consultation call with me to assess your situation together.
Casting Insights⚒️
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Vacuum Rheocasting Heat Sinks with Significantly Improved Performance
Published: NADCA – Die Casting Congress & Tabletop Exhibition
Co-Authors: Martin Hartlieb (Viami International Inc.), Jean-Claude Tawil & Stephan Bergeron (Dynatool Industries Inc.)
With increased performance requirements, the demand for heat sinks in industries like e-mobility, telecom, and electronics is rising. Heat sinks need high thermal conductivity; however, pure aluminum, despite its high conductivity (247 W/mK), is hard to cast and weak. Die casting alloys have lower conductivity (100-130 W/mK), while PM alloy A356-T6 and 6000 series extrusions offer 150 W/mK and 160-200 W/mK, respectively. Lowering Si content boosts conductivity but hampers casting intricate shapes.
Designers prefer heat sinks with maximal surface area for effective heat dissipation, favoring long, thin fins to enhance cooling. Die casting is advantageous for creating these complex shapes economically in single components.
High Vacuum Rheocasting (Comptech Process) with 30-45% solid fraction combines the benefits of PM alloys and low Si content alloys, achieving conductivity akin to 6000 series extrusions, primarily from recycled aluminum. It supports optimized designs with thinner walls and better mechanical properties. This paper demonstrates how vacuum Rheocasting via the Comptech-Process can help die casting meet the growing heat sink market’s needs, offering improved, cost-effective, and sustainable solutions.
New Addressable Applications for Rheocasting to Escape from an Oversupplied Market
Published: Solid State Phenomena Vol. 348
The market for aluminium HPDC castings has shifted due to the “Dieselgate” scandal, moving from diesel to petrol engines and then to hybrid and battery-powered cars, leading to a decline in demand for traditional powertrain components. As powertrain foundries move into the structural castings market, oversupply has driven down prices and margins, exacerbated by rising energy costs, causing a crisis for foundries. Implementing Rheocasting in existing die-casting cells offers a solution by enabling the production of high-wall thickness parts and electronic housings with fewer defects, lower production costs, and better crash performance. Rheocasting also benefits the telecommunications industry by allowing the production of more efficient and cost-effective cooling modules for 5G power electronics. Overall, Rheocasting opens new market opportunities, offering a cost advantage and high margins compared to gravity and sand casting.
What to learn from the world's most sustainable casting for Gigacastings
High solid fractions are key to best-quality castings
Published: Foundry Colloquium Aalen
This short presentation is about what you can learn from the world’s most sustainable casting about Gigacastings. You will get an idea of the cost savings by being sustainable and using Rheocasting on these large castings.
Goldcasting Podcast
The Goldcasting podcast shows how to turn Aluminium into Gold. We focus on making money in the foundry industry. The raging question is: Is there any money, or is it just squeezing everyone to save cents?
We think there is! So, we’re not talking about properties, microstructures, atoms, or casting parameters. We want to speak to everyone in our industry or who wants to join the foundry industry.
Latest Newsletter Articles
Presenting Rheocasting for Gigacastings
Discover how Casting-Campus brings Rheocasting expertise to the 4th China International Lightweight Industry Conference in Chongqing.
Approaches to and Challenges of Gigacastings
Explore the challenges of Gigacastings in the automotive industry, from supply chain constraints to quality control and material innovations. Learn how global OEMs are adapting to large-scale casting technology
Give a Kid a Hammer and the whole World becomes a Nail
Explore the key differences between HPDC and Rheocasting. Learn how each process impacts tool design, casting quality, and profitability, and discover when Rheocasting is the right choice for your foundry.
Become a Content Factory
Boost your productivity with time boxing, a powerful technique to batch content creation efficiently. Learn how to schedule focused sessions, harness creativity, and avoid last-minute stress for consistent, high-quality output.
The Foundry Boot Camp
Unlock the full potential of your foundry with the HPDC Efficiency Audit. The HPDC Boot Camp helps die-casting companies streamline workflows, benchmark performance, and integrate digital tools for maximum efficiency. Stay competitive by identifying hidden inefficiencies and driving continuous improvement.
CBAM introduces Emission Costs
Starting in 2026, the EU’s Carbon Border Adjustment Mechanism raises CBAM costs on castings. Learn how Rheocasting cuts emissions and boosts your competitiveness.
