High-pressure die-casting

With multiple aluminum and magnesium alloys, GF Casting Solutions sets top standards for high-pressure die-casting components, offering the entire value chain from raw casting to the final component.

Facts & figures

HPDC

Value add in high-pressure die-casting

Casting

Laser cutting

Heat treatment

CNC machining

E-coating & passivation

Assembly

Automation at GF Casting Solutions

Find out in our video how we improve our processes with digitalization and a high level of automation in the production of our high-pressure die-casting facilities

Each cast component gets a code

Find out how the data matrix code at GF Casting Solutions improves efficiency, ensures high quality, and enables sustainability when manufacturing lightweight components, such as shock towers. 

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1. The die-casting machine: A shock tower is cast in the die-casting machine. It will later connect the    shock strut to the body and structure of the vehicle.

The monitoring station: A central monitoring station is where all data for the parts being    manufactured and the machines converges. Here the processes can be continuously monitored.

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2. Stamping: The component receives its data matrix code, similar to having its own unique DNA.

3. Initial scan: The code is scanned by a camera. Starting here, the code will be scanned continuously.

4. Grinding: An angle grinder is used to manually remove the punch burr – the rough edges caused by the punching process.

5. Heat Treatment:  In a kiln, the component passes through different temperature stages. This improves ductility.

6. Measurement: An automatic measuring station measures the component and checks predefined measuring points. The component is manually reworked if necessary.

7. Machining: The code is scanned again before machining begins. A processing machine takes over once it has been ensured that everything is correct.

Autonomous driving: A driverless transport system takes the shock tower to the next station in a transport box. The electric pallet jack travels around 250 meters each time.

8. Coating: The component is coated in several dip tanks in sequence: first as a pre-treatment, then for e-coating. This process serves to improve the component’s resistance to solvents, corrosion, acids, and alkalis.

9. The 100% check: The component is now ready for final inspection. An employee scans the code. The traceability system verifies that all process steps have been carried out correctly. A shipping label is automatically printed if everything is correct.

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10. Shipping: The shock towers are packed in shipping boxes and then sent to the customer.

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Our key products

Structural parts

Lightweight solutions for crash-relevant, high function-integrated structural components

Powertrain

Weight-optimized parts for powertrains such as transmission housings

E-mobility components

High value added components for alternative drives

Industrial applications

Escalator steps and lighting housings with optimized weight reduction

Our development scope

With our central Research & Development department in our headquarter, Schaffhausen, Switzerland and in Suzhou, China, we want to support you with many years of experience, broad know-how and quality excellence in:

  • Material development
  • Process development
  • Design development
  • Validation & testing

Markets we serve

Light vehicles

Light vehicles

Lightweight structural parts, e-mobility solutions and powertrain castings for the automotive industry.

Light vehicles

Our high-pressure die-casting locations

Altenmarkt

We are specialized in the magnesium and aluminum die-casting solutions for the international automotive industry.

Herzogenburg

Aluminum high-pressure die-casting components for cars, trucks and industrial applications: structural parts, oil pans, housings etc.

Werdohl

We are experts for the machining of aluminum components for passenger cars and commercial vehicles.

Suzhou

High-quality lightmetal solutions: From the inhouse development over the tooling and stable high-pressure die-casting process up to machining and assembly.

Customer stories

Read more about our partnerships with Volvo Cars, Renault and Aiways and discover our solutions for the mobility of tomorrow!

Certifications

ISO 14001

Altenmarkt, Herzogenburg, Werdohl, Suzhou

ISO 45001 (OHSAS 18001)

Altenmarkt, Herzogenburg, Werdohl, Suzhou

ISO 50001

Altenmarkt, Herzogenburg, Werdohl, Suzhou

ISO 9001

Suzhou

 

IATF 16949

Altenmarkt, Herzogenburg, Werdohl, Suzhou, Pitesti/Scornicesti

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