What does it take to operate a Foundry successfully in 2025?⚒️
Learn what it takes to thrive in a declining market based on the Goldcasting Podcast
This week’s newsletter contains the following topics:
Handtmann and Spartan grew up in different markets. Yet, their recent trajectories show an almost mirrored response to the challenges of high-pressure die-casting's next era. Both companies have pivoted from the traditional, reactive "build-to-print" mould toward an upstream, design-driven role that places them at the core of their customers' engineering decisions. A comparison of their key messages in the Goldcasting Podcast reveals their strategies that explain the convergence.
Business-development engines
Neither firm waits for a request-for-quote to learn where opportunities lie. Handtmann has built a dedicated unit that studies global product trends, selects attractive component groups and then specifies the processes and competencies the group must master to win that work. Spartan identifies white-space projects and develops both products and processes well before sourcing cycles begin. In both companies, market analysis is not a one-off spreadsheet exercise; it is an embedded function that continuously feeds their innovation pipelines.
Technology bets are made ahead of orders
The payoff from this market intelligence appears in bold capital decisions. Handtmann's gigacasting press signals confidence that large structural castings will migrate to the region despite Europe's more cautious investment climate. Spartan, likewise, became the United States' pioneer user of Comptech's semi-solid slurry maker for Rheocasting, accepting the learning curve and tooling costs long before guaranteed volumes were on the table. By owning critical equipment early, both firms gain credibility and test data when OEMs begin to scout suppliers for next-generation architectures.
Multi-disciplinary engineering capability
Capital alone does not secure a seat at the design table; it must be underpinned by expertise. Handtmann has assembled an advanced engineering department that blends topology optimisation, vibration and strength simulation, flow modelling and rapid prototyping, allowing the team to deliver fully validated concepts rather than empty promises. Spartan mirrors this breadth with a central engineering group that supports all four of its plants, combining design, analysis and R&D to develop novel parts such as a one-piece aluminium brake rotor and to adapt Rheocasting until production-ready. Such in-house knowledge lets both companies discuss material choices, flow lengths or porosity targets with OEM engineers on equal footing, shifting the relationship from vendor to partner.
Pro-active engagement with design teams
Armed with hardware and know-how, both foundries approach customers well before drawings exist. Handtmann routinely drafts alternative concepts that challenge a client's baseline steel or multi-piece solution, then backs the pitch with physical prototypes at its own risk when necessary. Spartan follows a comparable route, seeking out OEM advanced-structures groups to demonstrate how Rheocasting or new alloys can lower weight or improve quality, rather than waiting for formal RFQs. Early engagement grants each firm influence over geometry, alloy and process decisions; advantages that rarely accrue to late-cycle quote responders.
Long-term talent pipelines
Both organisations recognise that cutting-edge equipment and upstream ambitions depend on people. Handtmann invests heavily in apprenticeships and dual-study programmes, treating skill development as part of its social responsibility and a hedge against Germany's tightening labour market. Spartan cultivates a family-like culture that retains experienced engineers and welcomes interns from local communities, ensuring continuity in know-how and a workforce comfortable with cross-functional collaboration.
Conclusion
Despite operating in different regulatory, cost and customer landscapes, Handtmann and Spartan have independently converged on a forward-leaning model: invest before the wave, build the engineering muscle to surf it, and work shoulder-to-shoulder with customers when the real design choices are made. Their example suggests that the future foundry will succeed less through hourly press rates and more through the depth of its market insight, the courage of its capital decisions, and the calibre of its engineering conversations with OEMs. European and North American peers still waiting for formal orders may find that by the time the RFQ arrives, the most attractive portions of the value chain have already been cast by companies willing to act first.
If you’re looking for guidance on strengthening your business development strategy, I’m here to help. Let’s connect and explore how to drive growth together. Schedule a Free Consultation Call on the website to learn more.
How to become the designated Expert!⚒️
In today’s casting landscape, marked by shrinking volumes, fierce price pressure, and heightened expectations, simply “being good” isn't enough anymore. To stand out, the foundries and suppliers must build a powerful brand presence online, leveraging social media platforms like LinkedIn, YouTube, and podcasts to demonstrate credibility and attract both customers and talent.
By creating content that educates and engages, such as process walkthroughs, engineering advancements, or sustainability success stories, you not only show what you do but explain why you're the best at it. Consistent, insightful content builds trust, positions your company as an industry leader, and keeps you top-of-mind when buyers or engineers seek solutions.
How Casting-Campus's Business Development Package Helps You Shine
Casting‑Campus positions itself not just as a technical consultant for Rheocasting but as a complete partner in marketing and market access for the foundry industry. Their Business Development Package offers support in ghostwriting your marketing materials, helping you reach targeted audiences and build your online presence, without having to become a marketing expert yourself.
By aligning positioning, marketing, and business development with their deep know-how in foundry processes, they help elevate your brand, from technical credibility to visible differentiation in content and narrative.
Why This Approach Works Now
Trust through visibility - Engineers and buyers see your expertise in action, not just your name on an email.
Expert positioning - Educational content shifts perception from “supplier” to “thought leader.”
Scalable reach - Online assets continue to attract leads long after they're published.
Hybrid advantage - Combining technical advantage with storytelling opens new markets.
Building this foundation often proves more efficient and compelling than cold outreach, especially when paired with professional support like Casting-Campus’s package. This is a unique combination of technical expertise and marketing finesse!
By strategically creating content and amplifying it with expert-backed marketing, you don’t just survive the crisis; you redefine your company’s brand and unlock new opportunities. Casting-Campus’s Business Development Package offers a streamlined, credible path to build that presence without reinventing the wheel.
Global Trends are reshaping the Future of Die Casting⚒️
The die casting industry is undergoing a transformation that is more fundamental than anything seen in the past few decades. For years, foundries across the globe have operated within a relatively stable system, responding to predictable volumes and traditional vehicle platforms. But those conditions no longer apply. A combination of global production shifts, the rise of electric vehicles, and fundamental changes in how value is created within the automotive sector have redefined the outlook for casting suppliers.
Global Production is shifting
One of the most significant developments is the redistribution of global car production. While the total number of vehicles produced worldwide has fluctuated over the years, a more important trend has emerged. It is the shift in regional production centers. Europe, once a pillar of global automotive production, is now facing a steep decline. Meanwhile, China continues to grow its market share, not just in volume, but also in technological leadership. The geography of automotive production is no longer centered in Germany, France, or Italy. Instead, the future is being built in Shanghai, Shenzhen, and other emerging EV hubs across Asia.
This geographic transition alone would be enough to shake the industry, but the transition to electric vehicles compounds it. The change is not limited to the powertrain. The architecture of EVs requires fewer castings overall, often by a factor of three or more. Traditional internal combustion vehicles relied on over 2,000 components. Some EVs today use fewer than 700. Even though the total aluminium weight per vehicle might remain steady or even rise due to large structural components, the number of casting operations per vehicle is falling sharply.
What this means is that the foundry industry is facing a decline not just in the number of vehicles served, but also in the number of article numbers per vehicle. In the past, every new model launched by an OEM brought with it dozens of potential casting jobs. That era is ending. Today’s EV platforms are designed with EVs in mind, not just converted ICE platforms, which remove complexity and, with it, cast volume.
The EV Transition matters!
Behind the scenes, a careful analysis of available data confirms this trend. The direction is clear. A combination of four critical metrics, overall vehicle production, the share of EVs versus ICE vehicles, the average aluminium content per vehicle, and the number of shots per car, reveals a sharp contraction in casting volume, particularly in the areas where most foundries have traditionally focused.
This is not a temporary shift. It reflects deeper forces at play within the automotive market. One of the most important is the changing perception of value. Where automakers once competed on mechanical complexity and engineering refinement, they now compete on software, connectivity, user interface, and digital services. The average consumer today is more interested in self-driving capabilities, screen size, charging speed, and app integration than in torque curves or suspension geometry. In this new context, mechanical parts are being simplified, standardised, or eliminated altogether.
For the die casting industry, this poses an existential question. If the core value delivered to customers is no longer mechanical, what role does the casting supplier play? Foundries that do not align themselves with the new vehicle architectures risk being left behind, not because of poor performance or low quality, but because they are no longer seen as essential. The parts they once delivered have simply disappeared from the vehicle bill of materials.
It is Time to Wake Up
The picture that emerges is one of accelerating change. The shifts in regional production, vehicle architecture, consumer expectations, and OEM priorities are converging. The casting industry must now respond not with incremental improvements, but with strategic redefinition. This is no longer a debate about automation levels or scrap rates. It is a question of relevance. And it is being answered right now in EV design studios, in battery platform discussions, and in procurement departments evaluating where and how to source the components of the future.
The first step toward adaptation is clarity. Foundries must understand the forces at play and acknowledge the scope of the transition. The data leaves little room for optimism based on the old model. The coming years will not bring a return to traditional casting volumes. Instead, they will demand a rethinking of what foundries make, who they serve, and how they create value. Only those willing to face that reality will have the chance to shape it.
Thank you for listening. We’ll see you in the next episode, where we’ll continue to bring you the latest insights and updates from the casting world. Don’t forget to ask questions, comment, or suggest future episodes.
Offers from Casting-Campus GmbH
Casting-Campus is all about helping you acquire new business through intelligent solutions, new technologies like Rheocasting, and sustainability.
Our services start with positioning your foundry. The next steps are to find unique solutions to market to existing and new customers and generate new profitable castings. In the meantime, we will improve your internal processes to accommodate the new solutions in your foundry. During the sampling process, we’re by your side, pushing the buttons to deliver the properties promised in the development process.
Workshops on HPDC process optimisation, Rheocasting and Sustainability
Business Development to acquire new Customers in the Foundry Industry
Strategy Development for Rheocasting and Sustainable Castings
Casting Experts on Demand - The Netflix of Knowledge
Support for part development: Address casting issues early in the design process
If this sounds appealing to you, visit the website for more information on the Consulting Services and schedule a Free Consultation Call. Let’s discuss what the right solution is for your topic of interest:
Historical Post
A weekly reminder of an old but gold article
The Second Life of HPDC Machines⚒️
We have all seen it for months: the overall foundry market is declining. The German foundry association reported an 11% decline in the first six months of 2024. And we have seen foundry groups, like the ae group, file for bankruptcy. Others are preparing to fire people or close down whole plants to avoid insolvency. Therefore, this article is not about how to sell HPDC machines, as no one is buying them because everybody faces the same trouble: “What castings can I put on these machines?”
Where did all the Castings go?
This question hits foundries with smaller DCMs much harder, as powertrain parts decrease in volume and smaller structural castings get integrated into larger sections. So, where can the second life of these machines be found when the portals are empty, or the target prices don´t even cover the costs?
It is a tricky situation that cannot be solved by the same method that got you into this mess. You might be used to shopping in high-end stores and interacting with the most desirable brands. But they barely know who you are regarding favours for new products. So, the nice OEM portals and contacts are pointless when filling out your small DCMs.
It is not better on the Tier 1 portals. There are even more foundries competing for the cheapest price. Now is the first time you must start looking around and looking for new businesses on your own to give your production site a second chance for future life.
And this market development will feel like a second-hand store!
You will see the casting equivalent of fashion trends that died a decade ago. They are so outdated that they are not even usable for a bad-taste party or translating into our industry language: They don`t fit your production mix. And there are a lot of them!
After much searching, you might find a piece that is not the most beautiful but fits roughly. But it is not the hidden gem of a designer piece you can instantly flip for a profit. The other issue is that many people are looking for that perfect piece, as many foundries are searching for the same products. And the price war repeats itself.
Where is the store that no one knows about?
This store is hidden in plain sight! But it is part of an exclusive club. You need a membership to get in. Let me explain:
In the last few years, we have seen HPDC run into its limitations. Providing high mechanical properties after 2.5 meters of flow length is a challenge. It is impossible to cast CO2 compressor housing in HPDC, which the EU requires from 2026 onwards. In addition, the electronic components in our cell phone towers or cars have become so powerful that the thermal conductivity of AlSi10MnMg is the bottleneck of computing power.
Rheocasting is the exclusive ticket into a new world of applications. The silicon content does not determine the castability in Rheocasting. An AlSi2 casts similarly well to an AlSi7. AlSi2 delivers thermal conductivities close to those of pure aluminium. You can cast 2.2 meters on a 600-ton DCM (yes, 600-ton, it is not a typo). With its laminar fill, you get helium-tight compressor housings and similar castings in your foundry. And there is way more to explore!
Now, you’re finally competing on a level all the others cannot. It feels like an unsupervised kid in a candy store instead of a dated second-hand shop. You can get lucrative contracts and be at the forefront of future developments.
Before you start dreaming, there are still strings attached. Just buying a machine will not get you into business. You must master the technology first, then implement the different requirements and prove them in trial castings for your customers.
That is a tiny price to pay for decades of profitable castings on your already-made investment!
Market development is a new task for foundries in their sales process and a massive challenge for most.
Do you want to learn more about Rheocasting and how it can level up your foundry? Learn how Rheocasting works and how to utilise it in the Rheocasting Masterclass: