Step-by-Step Guide to Technology Leadership
As the automotive industry races toward EVs and structural lightweighting, Spartan Light Metal is quietly leading a different kind of revolution, one rooted in Rheocasting and a distinctly pragmatic approach to innovation.
Unlike others chasing hype, Spartan focused on starting small, using existing tooling and building step-by-step. The result? They’re now the first U.S. company running Comptech’s Slurrymakers in production and are quickly becoming a go-to partner for OEMs seeking structural casting solutions.
1. Start Where You Are
Spartan didn’t wait for ideal conditions. They modified existing HPDC dies and ran real-world trials, even with perimeter-gated tools. Despite the limitations, they achieved quality comparable to conventional HPDC while gaining valuable insights into flow, gating, and porosity reduction.
Instead of investing millions upfront, they focused on learning by doing, generating wins and building confidence with every trial.
2. Flexible Technology, Lower Risk
Their use of Comptech’s slurrymaker was a strategic move. Installed with their existing HPDC cell, it enabled them to switch between traditional and semi-solid casting without requiring dedicated equipment or incurring long downtime. The 1600-ton cell operates in standard production by day and conducts Rheocasting trials during available windows. There is no disruption, just smart integration.
3. Parallel Tracks: R&D and Business Development
As Spartan built internal know-how, they also marketed to OEMs’ R&D and advanced engineering teams, not just buyers. Because Rheocasting unlocks new design freedom, the conversation had to start early in the development cycle.
This dual-track approach, which builds capability while driving demand, turned R&D into a commercial engine. With this approach, Spartan evolved from supplier to technology enabler.
4. From Innovation to Revenue
Rheocasting has helped Spartan not only reduce porosity and improve die life, but it has also led to patented innovations, such as their aluminium brake rotor, created with a NASA-derived alloy. These projects have opened doors to co-development with OEMs, proving that innovation can be a sales strategy.
As Chris Sleath said, “You take little steps to get little win after little win.” Those wins build trust, and trust drives programs.
5. Leverage Cooperation around the World
Spartan’s push for innovation doesn’t stop at their own walls. Through partnerships with organizations like NASA and KS Huayu Alutech, they’re extending both their technical depth and global reach. This strategy enables Spartan to lead in materials development, offering OEMs a seamless path to global production that combines U.S. innovation with international scalability.
A Blueprint for Foundries
Spartan’s approach is a lesson in how incremental innovation can lead to real transformation. Start small. Stay focused. Engage customers early. And above all, treat R&D as a growth engine, not a cost.
From modified tooling to a global footprint, Spartan is proving that Rheocasting is more than a process; it’s a strategy. And they’re leading it in the US.
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