High Pressure Die Casting

HPDC Expert on Demand

A recent study commissioned by European Aluminium has found that the average amount of aluminium used in European cars has increased by 18% from 174 kg in 2019 to 205 kg in 2022. The study predicts this trend will continue, with the average aluminium content projected to increase from 205 kg in 2022 to 237 kg by 2026 (+15.6 %) and 256 kg per vehicle by 2030 (+24.9%).

While the overall usage of aluminium is increasing, the number of parts could decrease due to larger and more complex high pressure die casting parts, such as megacastings, made from aluminium. Some claim up to a 75% reduction from around 1600 to just 400 high pressure die castings.

For high pressure die casting foundries, this shift presents both challenges and opportunities. On the one hand, the move towards larger and fewer parts leads to a massive decrease in demand for smaller, more traditional castings. On the other hand, it opens up new opportunities for foundries that can adapt and innovate.

Free Consultation

Do you need help unlocking the full potential of High-Pressure Die-Casting, Sustainability, and Rheocasting?

Casting-Campus GmbH helps you from the idea through the implementation into the production process. Book today a free consultation today to talk about your company’s potential.

From Positioning to Business Development to Series Production

In order to innovate your high pressure die casting foundry, we first need to define the direction you want to take your company. When direction is defined the targeting starts to find the innovative solutions that the future customers beg for.

Our mission is to find these gaps in the market and propel your high pressure die casting innovations from concept to reality. The “Casting Expert on Demand” package gives you access to crucial marketing and casting knowledge in the early stages of development. A key part is reviewing and adapting of the internal processes to successfully accommodate these new customers.

We specialise in guiding foundries, Tier 1 suppliers, and automakers through the intricate process of high pressure die casting, transforming ambitious designs into tangible, high-performance castings. From lightweight battery enclosures to intricate e-motor components, we ensure your components meet stringent quality, reliability, and efficiency standards.

But we don’t stop there. Our consulting services extend beyond the casting process itself, offering comprehensive insights and support at every stage of development. Whether you’re navigating material selection, optimising part geometry, or fine-tuning production parameters in the sampling and series production processes, we empower your team and drive success.

Our Approach: Tailored Strategies for Lasting Impact

At Casting-Campus GmbH, we understand that each high pressure die casting foundry is unique, with its own set of challenges, goals, and resources. That's why we don't believe in one-size-fits-all solutions. Taking over high pressure die castings from new industries is just one of many solutions that do not compete with other foundries.

Our expert works closely with you to assess your specific targets and develop a customised business development strategy tailored to your foundry’s requirements. Each foundry utilises different machines depending on their size and preferred customers for their solutions.

Our Services:

Comprehensive Assessment

We start by thoroughly evaluating your current operations, capabilities, and market positioning. This assessment forms the foundation of our strategic recommendations.

Strategic Planning

Based on our assessment, we collaborate with your team to develop a detailed roadmap for acquiring new profitable castings into your operations. From technology screening to process optimisation, we provide clear and actionable steps to maximise your success.

Content Creation

Developing a new market for your foundry requires strategically targeting the right people. A content-based social media strategy unlocks potential that goes beyond new customers. Think about attracting the best talents in the industry.

Technical Support

Implementing cutting-edge technologies requires more than just a strategic plan—it demands technical expertise. Our team offers hands-on support throughout the implementation process, ensuring a smooth transition and minimising disruptions to your production.

Training and Education

Empowering your team is essential for long-term success. We provide comprehensive training programs tailored to your staff's needs, equipping them with the knowledge and skills required to excel in the high pressure die casting environment.

Continuous Improvement

The journey continues once new products are ram up in your high pressure die casting foundry. We believe in ongoing support and collaboration to drive continuous improvement and optimise your operations for maximum efficiency and profitability.

Quality Issue Resolution

Over time, the production quality of your castings can drift to the negative side. The customer is already sending parts back, and an escalation is approaching. These escalations are massively expensive and damage your reputation at the OEM in the long term. In these times, it is crucial to get experienced support very quickly, which can help de-escalate the situation from day 1.

Working with Casting-Campus GmbH is a different Experience

One of the biggest hurdles to hiring a consultant is the unpredictability of costs. As a consultant, you earn more money the more time you need to complete your tasks. As the hiring company, you want results that are as quick as possible. So, there is a misalignment of interests, which causes a lot of friction.

That doesn’t happen with Casting-Campus GmbH as your consultant. We removed the friction and misalignment of interests. When you hire us, you pay a flat monthly fee for our remote Rheocasting Strategy Development. It is like the Netflix of Knowledge.

We share your interests. We want to quickly provide you with the best solutions while maintaining the highest quality levels. In addition, you can predict your project costs exactly. It is a perfect match!

You can cancel the service anytime if we don’t deliver the expected quality, but we will deliver outstanding comprehensive services because we want to have a long-lasting partnership that accelerates your success.

As a remote consulting service, there is occasionally a need for on-site visits. The monthly fee does not cover these visits for customer meetings, exhibitions, and workshops. But, even as a Netflix subscriber, you must pay for their studio tour. It is the same for this business model. We have to charge for that if you want us on-site. But as a partner, you get a discounted rate.