From Process Complexity to Market Opportunity

Rheocasting has experienced waves of interest and innovation over the past decades. Despite its technical merits, the adoption of Rheocasting has historically never happened, first due to the intricacies of process control and, more recently, due to market visibility and business development constraints within foundries.

Diverse Approaches, common Goals, different Outcomes

At its core, Rheocasting involves forming a semi-solid slurry. Unlike traditional “liquid” High-Pressure Die Casting, Rheocasting slurries contain globular solid particles, giving them unique thixotropic properties similar to ketchup: fluid under shear stress but thickening when static.

Multiple technologies exist to achieve this slurry state. In a patent research study, 87 varieties were identified. 86 of the 87 patented Rheocasting technologies relied on stringent temperature control. This precise thermal regulation proves the fatal downfall due to its sensitivity to the melt chemistry. Each batch has a slightly different chemical composition that changes the liquidus temperature and, therefore, changes the solid fraction, creating an unstable production process.

Only Comptech’s RheoMetal process circumvented this complexity, leveraging identical chemical compositions between the EEM (Enthalpy Exchange Mass) and the liquid metal. RheoMetal stabilised the Rheocasting process by eliminating temperature-controlled slurry production, enhancing consistency and commercial viability.

Today’s Challenges are Visibility and Marketing Capabilities

If you didn’t fall for the false claims in the marketing material of these temperature-controlled processes, the Comptech Rheometal process has its challenges, too. These challenges have nothing to do with the technology, which works rock-solid. It is a different aspect: limited visibility and ineffective business development within the foundry industry.

Traditionally reliant on existing relationships and technical excellence, the die-casting sector struggles to communicate its capabilities, remaining largely unknown outside our bubble. Taking the initiative fell out of the priorities for many foundries decades ago. They just waited for the OEM/Tier 1 to call them and dictate what to do.

This passive marketing approach severely restricts Rheocasting’s broader adoption. Like any advancement and new technology, Rheocasting requires proactive marketing strategies beyond static brochures or datasheets. Modern marketing should emphasise storytelling, digital engagement, and strategic outreach.

Cost Advantages as a Marketing Edge

An often-overlooked selling point for Rheocasting is its significant cost-saving potential. Due to improved flowability and feeding characteristics, Rheocasting slurries enable foundries to produce complex, large components on 20 to 30% smaller machines.

Smaller machines decrease initial investment costs and reduce operating expenses, energy consumption, and tooling wear, further compounding cost advantages. Beyond cost savings, Rheocasting boasts substantial sustainability benefits, which resonate increasingly with current market demands:

• Reduced furnace temperatures and energy consumption.

• Ability to utilise low-silicon, post-consumer secondary alloys with lower carbon footprints.

• Longer tool life and lower rejection rates, enhancing overall environmental performance.

• Reduced material usage through thinner, structurally optimised walls.

Final Thoughts

While Comptech Rheocasting as a technology has successfully navigated past technical barriers, its future growth hinges on proactive marketing and strategic visibility. Foundries must abandon their traditional passive approaches and start actively engaging with broader audiences and telling compelling stories about their capabilities and advantages.

Leveraging the substantial cost and sustainability benefits as cornerstones, Rheocasting could significantly expand its market presence, proving itself technically superior and commercially essential.

Ready to explore how Rheocasting can enhance your competitive advantage? Schedule your Free Consultation Call down below to see how Rheocasting helps your product portfolio.