‘This technology is hugely dynamic’: Global Giga-Casting Congress in Kassel promises exciting insights

Gigacasting has been described as revolutionary for the automotive industry. How do you assess the current development and what influence does this technology have on the industry as a whole?

Martin Fehlbier: Gigacasting is no longer in the development phase at many OEMs but is already being used for series applications in the front and rear end as well as battery boxes. In the future, some companies, particularly Chinese electric vehicle manufacturers, are planning to produce the entire vehicle underbody, which offers particular advantages due to its flat geometry, from a single casting. 

While the first gigacasting casting cell was only put into operation by Tesla in 2020, by 2023 there were already around 40 units worldwide and by 2025 the number will rise to over 100. BYD recently announced that it intends to install two 9,000-tonne gigacasting casting cells per month this year, perhaps even up to 100 units in total. Cell sizes of 20,000 tonnes clamping force and above are already being discussed. This shows that the technology is hugely dynamic and that more and more OEMs are jumping on the bandwagon or are looking into it intensively. It is hoped that by replacing countless individual parts with a single large casting, production costs can be roughly halved. Others are also hoping for a lightweight construction advantage of 10 to 15 per cent. 

What goals are you pursuing with the congress and what insights do you hope to pass on to the participants? 

Martin Fehlbier: The OEMs taking part in the congress come from Asia, North America and Europe. It will be very exciting to see their views and future strategic direction on gigacasting. In addition, plant manufacturers, casters, important suppliers and service providers will have their say or be represented on our exhibitor market, without whose specialist knowledge the introduction and implementation would never be possible. 

As we all know, it’s the little things that cause big problems, so very critical, perhaps even unresolved aspects and thus challenges for research will also be addressed. We hope that the curtain on gigacasting will be raised further for all those involved in the congress and that the perspectives and approaches presented, as well as the possible solutions, will contribute to a deeper understanding of the complexity of the overall process.

The congress is aimed at an international audience. How important is global dialogue for the further development of gigacasting technologies?

Martin Fehlbier: The development of gigacasting is not taking place across the board, but is based on the local activities of individual OEMs and their suppliers. Many suppliers are therefore very internationally orientated and develop special solutions for gigacasting. To be presented with these diverse global activities by the participants themselves, i.e. the OEMs, plant manufacturers, mould makers, casters and post-processors, and to be able to discuss them internationally and to be able to ask specific questions, is a great opportunity for all participants to exchange ideas, which does not happen every day.

The congress programme covers a wide range of topics - from OEM strategies to new tool and alloy concepts. Is there a focus that is particularly close to your heart?

Martin Fehlbier: Every presentation is individual and therefore valuable. I like the fact that the strategy and perspective of OEMs and foundries are discussed, right through to post-treatment and total cost of ownership, but also aspects relating to the CO2 footprint or new developments in the large-scale casting of magnesium components in China, keyword thixomoulding. As the Chair of Foundry Technology, we are naturally interested in all these topics from a researcher's perspective. However, we also have an intrinsic motivation to strengthen Germany and Europe as a business location. We are convinced that we can learn from each other and that there is a win-win situation for everyone. We therefore hope that we can make a small contribution to strengthening the foundry industry with our independent university platform for technological exchange.

In addition to the technical presentations, there will also be an opportunity for socialising at the Foundry Evening in the Alte Brüderkirche. What role does networking play at an event like this?

Martin Fehlbier: The Alte Brüderkirche offers a particularly beautiful ambience with music and good food. We have planned the interior in such a way that it will be possible to exchange ideas in a relaxed atmosphere with an average of up to 20 people. In addition to the professional exchange, we naturally hope that our event will also make a small contribution to international understanding in these turbulent times.

Thank you very much for the interview!

Diverse programme for experts

The Global Giga-Casting Congress offers a comprehensive range of topics. Whether strategies of OEMs and suppliers, concepts for vehicle design and high-pressure die casting systems or innovations in alloys, machining processes and simulation techniques - almost all aspects of gigacasting will be discussed. Practical reports and research results will complement the event. With its open architecture and central location, the Campus Centre of the University of Kassel at Holländischer Platz is an inviting place to network. 

Registrations are still possible until 21 February: register here