Bühler unveils its megacasting solution Carat 840 to customers for the first time in Europe

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Bühler has been active in die casting for nearly 100 years. Megacasting is a further development of the structural process (complex, thin-walled parts produced using die casting) which Bühler has driven since the early 2000s. With about 900 machines in operation, Bühler’s Carat series, with locking forces ranging from 10,500 to 92,000 kilonewtons (kN), is the most successful solution on the market and is bringing megacasting production to the next level.

At the event in St. Valentin (Linz), Austria, Bühler showcases its megacasting technology with 8,400 tons locking force to international representatives of the die-casting and automotive industry for the first time in Europe. With a height of 7.6 meters and a floor area of around 160 square meters, the Carat 840 can inject over 200 kilograms of liquid aluminum into a die within milliseconds.

Reducing complexity in automotive manufacturing

The production of larger and more complex parts is considered groundbreaking by many car manufacturers who are moving in this direction or thinking about adopting that solution. Megacastings reduce complexity in production by enabling between 70 to 100 parts to be replaced by a single die-cast part. These single-piece castings will generally be produced close to the automotive assembly line, which allows for better integration and reduced transport.

“The future of the automotive market is being shaped by various forces. The main factors today are reducing complexity, increasing productivity, and improving sustainability,” says Cornel Mendler, Managing Director Die Casting at Bühler Group. “Our event is a unique chance for our customers and partners to experience the innovative technology behind megacasting and network with members of the industry from across the entire value chain.”

Martin Lagler, Director Global Product Management & Marketing Die Casting at Bühler Group, goes further and says: "By stepping into this market and supplying OEMs directly, our presence in the automotive industry has become stronger. It is therefore important for us to show the industry what we can offer and how we can work together on future-proof solutions for lighter and more sustainable vehicles."

Sustainability as a driver for aluminum die casting

Apart from the reduction in complexity, aluminum castings have the potential to drastically reduce CO2e emissions in manufacturing, with fewer processing steps and especially when using renewable energy or electric melting. CO2e per part is also reduced by minimizing waste and using low CO2e aluminum alloys. The aluminum that goes into overflows and runners can be remelted directly and reused in the die-casting cell, thereby avoiding transport for recycling.

Our internal studies show that compared to benchmark emissions today, megacasting offers the potential to reduce CO2e emissions by 70%. This can be achieved by using aluminum alloys with low CO2e footprint, avoiding fossil fuels for melting, and powering all operations with renewable electricity. This allows car manufacturers to reduce the carbon footprint of their products," explains Martin Lagler, Global Director Product Management & Marketing Die Casting at Bühler Group.

The power of collaboration

Together with partners, Bühler rethinks, designs, and commissions entire solutions and can therefore offer process solutions from ingot to the body shop. At the event in Austria in June, partners involved in the process will present their area of expertise within the die-casting cell. Visitors have the chance to gain insights into die design, efficient melting of aluminum, tempering and spraying of the die, and much more. As the core of the cell, the Bühler Carat series enables parts to be cast at the highest quality.

Bühler Advanced Materials – partner for the automotive industry

Bühler’s Advanced Materials business not only provides die-casting solutions for the automotive industry but also actively engages in the fields of battery production and sensor coating, thereby offering key solutions for the vehicle of the future. The Grinding & Dispersing business is heavily involved in the production of battery slurries solutions for electric cars. Bühler Leybold Optics is driving solutions for advanced driver assistance systems (ADAS) coatings. "With the broad portfolio in our Advanced Materials business, we offer innovative and state-of-the-art solutions for the automotive industry," says Marcel Natterer, CEO Advanced Materials at Bühler.

Learn more about Bühler’s megacasting solutions: The colossus of Die Casting

Learn more about the benefits of aluminum for the automotive industry: Aluminum - The lightweight contender