How to Disrupt the HPDC Market

In every industry, disruption challenges the status quo, forces us out of our comfort zones, and demands innovation. Whether it’s new technologies, market shifts, or changing customer expectations, those who adapt to disruption thrive, while those who resist risk are left behind.

With Gigacasting, disruption has already begun reshaping car production and making HPDC cool again. This will not affect most foundries, as their machine sizes are different, but our industry is about to undergo more changes.

Major legislation come in 2026

First, we have changed the requirements for EVs. The car’s higher weight and tightness requirements made casting substantially complex. Two more changes will be visible from 2026 onwards. On January 1, 2026, two laws became active in the EU: the CBAM and the F-Gas-Ban. Not being sustainable becomes a cost factor when CBAM transitions from monopoly money into Euros. This will primarily affect Tier 1s and OEMs as many of their purchasing departments still neglect these costs.

Currently, at least 500 HPDC machines in Europe produce climate compressor housings for R134a. This Tetrafluorethan molecule stands in the way of a new vehicle platform being approved or not. The alternative is CO2 or R744. The smaller molecule brings the advantage of a higher efficiency of the entire climate system. However, the operating pressure needs to change. R134a systems operate at pressures of 13 to 16 bars, whereas R744 operates at 130 to 160 bars. An HPDC casting, even with impregnation, can hold the CO2 as well as a paper bag can hold water.

A 10x increase in pressure by making the same production method unusable is a disruption of the market. Now, how can you profit from that shift?

Rheocasting is the answer!

Adding a Slurrymaker to your existing HPDC machine enables you to produce entirely new property ranges. In Rheocasting, you can produce compressor housings for R744 that are Helium pressure tight at 160 bar without impregnation. With that small addition to your process chain, you can outperform an entire industry and gain as much business as you can handle from the 500+ HPDC machines.

What works for CO2 compressors also works for larger structures like battery trays or welded constructions. These are often welded and cannot be impregnated. But without the impregnation, HPDC castings leak and fail the testing. With Rheocasting, this scraping of the construction at the end of the process chain goes away.

Business Development made easy

In times when the Tier 1 and OEM portals are empty, the art of business development comes into play. When you compete on HPDC castings among all other foundries, the only way you’re getting new business is by starting a charity donation program to support your multi-billion OEM customer and giving away castings for less than production costs. And who wants that?

It is much more appealing to enter the discussion with a solution to their existing and/or upcoming problems. If you want to join the foundries that thrive in this crisis, check out the Rheocasting Expert on Demand program. Schedule your free Consultation Call down below.