Gigacasting Batteries with a Twist

The race to electrify the roads has never been more intense. Every automaker is looking for that competitive edge. For many, the next frontier is casting large, leak-tight battery boxes. Traditionally, you’d think you need a massive 6100-ton or bigger die-casting machine to achieve these gigacasting batteries. That is at least what the battery manufacturers require. However, the Megacasting capacity in Europe is not given. But thanks to Rheocasting, you can deliver leak-tight battery housings on a 4400-ton machine or even smaller.

The leak-tight Requirement

Battery castings are among the most demanding parts in automotive manufacturing. They often have thick walls, 5 mm or more, that need to withstand extreme conditions. And here’s the catch: They must be absolutely leak-tight to protect the battery cells, the environment, and the people driving over them.

In standard High-Pressure Die-Casting, you fill the die with fully liquid aluminium. The metal’s solidification shrinkage (6.6% from liquid to solid) can create porosities. All this results in potential leaks you might only discover after all production steps (casting, trimming, heat treatment, straightening, machining) are completed. If the final part fails, an impregnation repair process might patch some spots but not all. Worse yet, some castings must be scrapped entirely, destroying your margins.

Enter Rheocasting

With Rheocasting, you’re no longer pouring fully liquid metal. Instead, you use a semi-solid slurry containing solid globulites that reduce overall shrinkage. This thixotropic slurry flows beautifully under shear forces. Gone are long dendrites that block feeding. The result? Near-pore-free microstructures and fewer repairs or scrap parts. That’s more profit in your pocket and higher confidence in your casting quality.

Leak-tightness isn’t Rheocasting’s only party trick; it also allows you to reduce the size of your die-casting machine by around 30% compared to HPDC. Conventional HPDC needs higher clamping forces to manage large projected areas at high metal pressures.

Still not convinced? Consider this: investing in one mega-machine ties up both capital and floor space. Multiple, maybe already existing, medium-sized machines using Rheocasting can achieve an even greater output. You spread your risk, streamline maintenance, and keep operating costs manageable.

Ready to Scale Down and Power Up?

Rheocasting is more than a production hack; it’s a strategic pivot toward lower investments, advanced process control, and better parts. Whether you’re a foundry producing EV battery housings or an OEM looking to secure a supply, switching from HPDC to Rheocasting can be a game-changer.

At Casting-Campus GmbH, we guide you through every phase, from concept to casting, so that you can bring leak-tight battery housing on your existing machine pool to life. Schedule a free consultation below to start your Rheocasting journey with the Rheocasting Expert on Demand package. Your bottom line and your customers will thank you.