The use of lost sand cores enables complex geometries with hollow structures and undercuts that cannot be produced in die casting. This also allows innovative concepts such as pack-to-open-body (cell-to-pack) solutions to be realised.
During casting, the mould packages are transported on rotating transport pallets with integrated permanent mould parts via roller conveyors to low-pressure casting machines. Pressure-assisted laminar mould filling is achieved via one or more riser pipes. The low-pressure casting process offers an advantage in terms of material characteristics compared to die casting due to directional solidification, as well as further technological incentives for variations in sands, binders and coatings.
Cost-effectiveness and stable processes
After process maturity, the concept part was subjected to a cost benchmark and evaluated using a cost analysis. The basis was a production of 250,000 pieces per year over a 7-year period.
The investment costs in the plant technology turned out to be about 30% lower than in GIGA casting. The manufacturing costs per part are comparable to GIGA die casting. For smaller series, the sand casting process offers significant cost advantages over die casting due to significantly lower tooling costs.
The material properties and wall thicknesses of the components are also at a similar level. High-quality cast parts can be produced through laminar mold filling and directed solidification. Die-casting challenges such as pull or adhesion points are avoided.
Advantages at a glance
MEGA sand casting is not only technologically but also economically attractive:
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Core shooting machines available in sufficient sizes: The technology is market-ready and can be used for large-area components.
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Proven core package process: Foundries are already familiar with the processes.
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Existing infrastructure: Much of the peripheral and manufacturing equipment is already in place.
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Tool-free production through 3D sand printing: Individual parts and small series can be produced flexibly and almost cost-neutrally.
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Realisation of special contours: Additive manufacturing allows geometries to be realised that would no longer be possible with conventional tools.
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Automated manufacturing processes: The use of robots and logistics systems ensures consistent quality with low personnel dependency.
The future knows no limits
The transformation in automotive casting presents new challenges for companies in the foundry industry, to which we must respond with innovative solutions. Ecological mobility requires lightweight construction and efficiency to minimise CO₂ emissions and make optimum use of resources. At the same time, the principle of "form follows function" demands maximum design freedom, which is often not achievable with permanent mould-bound die casting processes.
Advancing digitalisation and the development of software-defined vehicles (SDVs) are placing new demands on structural components. Integral components play a decisive role in enabling functional and weight-efficient design. New vehicle concepts such as open-to-pack architectures and advanced battery cells also require flexible manufacturing technology that can adapt to changing market requirements.
Another decisive factor is the use of artificial intelligence, which can accelerate technological developments and significantly shorten development times. Companies that have a high degree of production flexibility and can respond quickly to new market requirements will secure a competitive advantage in the long term. At the same time, the qualification and promotion of skilled workers is becoming increasingly important. Only with specialised and well-trained employees can companies maintain their innovative strength and create attractive, future-proof jobs.
Conclusion
The joint project by HA and Laempe clearly demonstrates the enormous potential of MEGA sand casting for automotive lightweight construction. Foundries not only gain an economical alternative to GIGA casting through this process but also a new business perspective. Through innovative technologies and collaborative partnerships, HA and Laempe support the industry in developing sustainable and flexible solutions.
The future of vehicle construction is characterized by new materials, production methods, and digitalization – with MEGA sand casting, a decisive step towards efficient and flexible manufacturing could be taken.
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Dipl.-Ing. Franz Friedrich Butz | Managing Director | Hüttenes-Albertus Chemische Werke GmbH (HA Group)
Dipl.-Ing. Rudolf Wintgens | Managing Director Technologies | Laempe Mössner Sinto GmbH
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Hüttenes-Albertus Chemische Werke GmbH
The HA Group is a leading global manufacturer of chemical products for the foundry industry. The family-owned company, which has been in business for over 100 years, focuses on research, modern technologies and close cooperation with customers and partners to develop forward-looking solutions. Hüttenes-Albertus (HA) offers a wide range of high-quality materials for mould and core production as well as comprehensive services. With around 1,800 employees in over 30 countries, the HA Group has a strong international network with its own production facilities, laboratories and sales companies.
https://www.ha-group.com
Laempe Mössner Sinto GmbH
Laempe Mössner Sinto GmbH is the global market leader for core making technologies in the foundry industry and offers a comprehensive portfolio of machines, automation solutions and services. Since its foundation in 1980, the company has continuously developed through innovation and expertise. In addition to automatic core shooters, sand mixers and control systems, Laempe implements turnkey core shops according to customer requirements. The company serves numerous industries, including the automotive, mechanical engineering and electric motor industries. With around 300 employees, its own sales offices and 25 partners worldwide, Laempe offers first-class service and global support.
https://www.laempe.com
