Casting

Our casting capability spans high-pressure die casting (HPDC), structural die casting and emerging mega-casting cells. These processes produce large, thin-walled aluminum parts that consolidate what used to be dozens of stamped and welded components into a single, geometrically optimized node.

Structural castings are used for shock towers, rear underbody nodes, front cradles and — increasingly — full battery-enclosure trays. Mega-casting takes this to the extreme, replacing entire underbody sub-assemblies with a single casting that reduces weight, joint count and warranty risk.

Alloy selection, vacuum-assisted process control, in-line X-ray inspection and heat-treatment (or T-free vacuum HPDC alloys that skip heat treatment entirely) allow us to hit demanding elongation, yield and weldability targets — critical for parts that must both crush predictably in a crash and accept downstream welding or self-piercing rivets.

We work with customers from early CAD, running casting simulation (mold filling, solidification, distortion) in parallel with structural FEA so the part is manufacturable and performant on first tool-out.