Champions League Quality in Megacasting

Employees at Handtmann are examining a die-cast component placed on a coordinate measuring machine.

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

Automated ZEISS opitcal 3D scanner is scanning a large die-casting part.

From challenge to solution: Handtmann’s quality strategy in megacasting

Here too, Handtmann must pioneer, as established processes, methods, and devices reach their physical and technical limits as soon as components are several meters in size and have complex, delicate structures. Sandro Langer, head of quality control, explains: “For megacasting, we need larger devices, new processes, and a quality logic that is designed for fast, understandable feedback. In addition, it was important to us to connect the various devices and standardize the measurement processes across all locations.” In the foundry's measuring room, which must also fit the new dimensions of their megacastings, the company relies entirely on innovative solutions.

A die-cast part is being inspected on the ZEISS PRISMO coordinate measuring machine.

The 2D X-ray system ZEISS OMNIA GC provides a complete X-ray inspection of large structural cast components without having to destroy them. The system reliably detects porosity, shrinkages and internal defects throughout the entire component volume, allowing an early decision to be made as to whether a part can be further processed. The automated 3D measurement system ZEISS ScanBox optically captures the entire component‘s surface and visualizes surface deviations between the actual 3D coordinates and the CAD data ensuring that warping and dimensional errors are immediately apparent. Automation with robot technology ensures reproducible results in a short time — ideal for quick feedback loops during the process. Finally, the coordinate measuring machine ZEISS PRISMO enables high-precision tactile measurements even on stationary, large megacastings. This allows critical functional dimensions and machining tolerances to be reliably verified, which are crucial for OEM approvals and further mechanical processing.

“When it comes to megacasting, we are playing in the Champions League, also in terms of requirements - and for that we need ZEISS as our partner.”

Sandro Langer 
Head of Quality Control at Handtmann

Employee at Handtmann is preparing the part for X-ray inspection with ZEISS OMNIA GC.

Ultimately, it was also crucial that most automotive manufacturers themselves work with ZEISS. As a benefit, measurement coordination becomes easier, results more comparable, and approvals faster. Sandro Langer comments: “When the customer measures with ZEISS and we measure with ZEISS, there is simply no room for misunderstandings or discussions.” At the same time, Handtmann was looking for a partner that offers long-term investment security and supports technological development. For plant manager Jens Hansmeier, it was clear that quality assurance must be based on a provider “that will still be setting standards in five or ten years time.” The extensive portfolio and fast support rounded off the picture. Sandro Langer sums it up as follows: “When it comes to megacasting, we are playing in the Champions League, also in terms of requirements - and for that we need ZEISS as our partner.”

Engineer inspecting large machined casting in factory.

Handtmann: Champions League Quality in Megacasting

One cast, many benefits

More on this topic: Giant precision

Handtmann: Champions League Quality in Megacasting

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One cast, many benefits​

More on this topic: Giant precision

One cast, many benefits