Resource efficiency

Thanks to many years of know-how and the ideal combination of design, materials and manufacturing processes, we are able to make components lighter.

Focus on climate action and resource efficiency

Reducing GHG emissions through design and material composition   

Leveraging bionic and lightweight design principles, continuously improves the weight of our components. This means, that less raw materials are used during the manufacturing process, leading to reduced GHG emissions throughout the entire life-cycle of a product. ​

Especially important for automotive applications, where weight reduction not only means a reduction in fuel consumption and the associated reduction in emissions, but also has a positive impact on driving behaviour. ​

 

Thinking towards a circular economy

Already today secondary aluminium and iron scrap play a major role in GF Casting Solutions manufacturing processes, with excellent rates of recycled materials used. ​

Together with our customers and partners, we work on new concepts to further increase the usage of recycled material to the highest extend physically possible. ​

Within the Sustainability Framework 2025 GF further focusses on increasing circularity and closed recycling loops, by leveraging the long-term casting expertise of our global foundries. 

 

Advantages

Shock Tower

Reducing CO2 emissions

Shock tower: Substitution of 10 sheet metal parts

-45 % weight reduction
1.3 g/km
375,000 t CO2*

*over 8 years vehicle lifetime

Shock Tower
Front Cover
Magnesium instead of aluminum

Magnesium is the lightest metal that can be used in mass production and is a very special material for us. Thanks to its specific density, it can save almost 30 % in weight compared to aluminum. In the drive area, we have succeeded in reducing the weight of the control box lid by more than 45 % simply by using magnesium and thanks to possible refinements and wall thickness reductions.

Substitution

Thanks to the high geometric freedom of casting, several components can be substituted with just one casting. In the body area, for example, we were able to replace up to 12 individual sheet metal parts with just one cast part and reduce the weight of the shock tower in die-cast aluminum by almost 40%.

Material know-how and bionic design

With our developed cast iron material SiboDur, the mechanical properties of the cast iron parts could be significantly improved. Thanks to the combination of SiboDur and bionic design, we have succeeded in achieving a weight reduction of up to 32% for chassis parts such as steering knuckles and wheel carriers compared to conventional castings.

More Topics related to Lightweigting:

Learn more about sustainability at GF Casting Solutions!

Sustainability

GF Casting Solutions focus is on designing and manufacturing products and solutions with environmental and social benefits. We take climate action and address environmental & social responsibility in our sites and in our global supply chains.