How to Start with Rheocasting? - Part 2

The easiest way to start with Rheocasting is to build on what you already know. In the first part of this article, I demonstrated how to do it for your existing parts, including those in the 226, A380, and 46000 alloy series. Now, we use external factors that cause radical changes. Especially when changes in regulations trigger these transformations, the opportunities present themselves and cause a rift. That is your chance to enter this market, as in every adaption process, not all make the transition.

New parts with Rheocasting

In that market situation, any new business is highly appreciated. So, many people look into Comptech Rheocasting to acquire new business. But how do you get started without falling into the typical pitfalls?

The unsatisfactory answer to that question is, it depends. The situation at each foundry is different. There are various experiences, machine sizes, production pipelines, and post-processing steps. So, what is the best way for you is impossible to generalise. However, the Rheocasting Workshop from Casting-Campus GmbH can provide you with the knowledge and clarity to make that determination. Inquire for more information by scheduling a free consultation call.

At a top level, there are two directions to approach Rheocasting, and both ways aim to gain an unfair advantage over your competitors.

The F-Gas Ban starts 2026

In 2026, the EU is banning fluorinated gases like R-134a, prompting a major shift in the automotive industry toward CO₂ (R-744) systems. These operate at far higher pressures, up to 190 bar, making traditional high-pressure die-casting compressors insufficient due to porosity and leakage issues. Even impregnation treatments can’t reliably solve this.

OEMs and Tier 1s urgently need new manufacturing partners that can meet these demanding requirements. Forging offers leak-tightness but is costly and limited in capacity. Low-pressure die casting enhances part integrity but falls short in terms of speed and scalability. Foundries relying on HPDC for compressor housing programs risk losing that business unless they adapt to the new requirements.

Comptech Rheocasting offers a smarter path forward. By casting a semisolid aluminium slurry, the process drastically reduces shrinkage and porosity. The result? CO₂-capable castings that pass even the most stringent Helium leak tests.

Crucially, Rheocasting is a melt preparation process for high-pressure die casting. It works with your existing HPDC infrastructure, requiring only an investment in slurry-making equipment, not a complete production overhaul. You can easily switch between Rheocasting and HPDC by changing the tool. This flexibility and properties lets you offer OEMs the performance of forging at the cost and scalability of die casting.

Now is the time to act!

Foundries that transition early will be best positioned to secure new partnerships, boost revenue, and lead the transition to high-performance, leak-tight casting. Also, stay tuned for part 3 of this series.