Handtmann: Champions League Quality in Megacasting

A few years ago, Handtmann, a family-owned company in Germany, prepared for the future of metal production by making a significant investment in a megacasting facility. It was a decision that paid off: car manufacturers from all over the world quickly lined up to have large castings manufactured by Handtmann in Germany. However, the pioneering work in casting also extended to measurement technology and quality assurance, as megacasting presents completely new challenges in these areas. To meet these challenges, Handtmann relies on optical, tactile and X-ray solutions.​

Handtmann has had its roots in Biberach for more than a hundred years, and this is evident in every corner of its production facility: highly specialized and developed from generation to generation. What began in 1873 as a small metal foundry is now a globally active technology group in family ownership, currently managed by the fifth generation. Light metal casting is one of the company's main pillars. Originally known for classic aluminum die-cast parts such as oil pans and transmission housings, Handtmann has evolved over the decades into one of the leading suppliers of complex structural components. Today, Handtmann foundry is a true pioneer. It is the first foundry supplier in Europe with its own megacasting machine, which enables the casting of very large, highly integrated aluminum components in a single shot.​ 

One cast, many benefits​

Instead of casting and machining many small components and then assembling them in several stages, megacasting produces a complex structural component in a single shot. This results in significant advantages. First, megacasting dramatically reduces production time. Previously many parts had to be produced in parallel, temporarily stored, made available, and welded, today a complete module — such as a front or rear end — can be produced in around 100 seconds. Second, the technology enables significant weight savings by eliminating joining points, reinforcements, and overlapping material zones. Less mass means more range for electric vehicles and thus a tangible competitive advantage. Third, megacasting reduces costs because a single component replaces several hundred tools, fixtures, and machining steps.​

At the same time, megacasting also brings new challenges to the production and quality process. Large, highly integrated components are much more sensitive to any process fluctuations. Even in the casting process itself, temperature distribution, filling behavior, and solidification have a greater impact on the result. Whereas a smaller component can compensate for certain fluctuations, large castings immediately run the risk of warping, unevenness, or dimensional deviations. The components are large but thin-walled and therefore sensitive to heat, cooling cycles, or local material stress.​

In addition, classic casting defects such as porosity, shrinkages, blowholes, and cracks have a greater impact in megacasting. A local defect can compromise an entire structural element. Therefore, measurement technology is needed that can assess the entire volume of the component, rather than focusing solely on specific sections or individual measurements. Another factor that is often underestimated is handling. A component measuring several meters cannot simply be picked up, turned, or measured like a small casting block. Incorrect handling, improper storage, or slight deformations during transport can already cause measurable distortion.

Learn more about quality assurance for castings here.