Casting technology

Innovative metallic casting processes in the context of casting 4.0

Our focus is on the casting of metallic materials, whereby we combine expertise in indirect additive manufacturing, molding materials, process development and analytics. This combination enables us to conduct interdisciplinary research that develops new solutions for the challenges facing the casting industry. In doing so, we attach great importance to the responsible use of resources.

Our aim is to increase the efficiency and quality of casting production, for example through automation and digitalization solutions, and to increase flexibility and productivity in production. Intelligent systems enable us to react more quickly to market changes and implement individual customer requirements.

We also research and develop new materials and alloys that meet the requirements of industry. We cooperate with companies and research institutes to make our progress marketable and promote innovative approaches.

Together with the Chair of Metal Forming and Casting of the Technical University of Munich, we form »Foundry Technology Munich«.

This partnership strengthens our research platform and combines basic and industry-oriented approaches.

In summary, our casting research not only contributes to technical innovation, but also to the sustainable development of the industry. We continuously adapt to new challenges and trends in order to ensure the relevance and sustainability of casting technology and lead the industry into a successful future.

 

Materials for Casting Technology

3D Sand Printing: Sand Based Additive Manufacturing of Cores and Molds via Binderjetting

 

Analytics

  • Mechanical tests
  • Chemical analyses
  • Thermoanalytical tests
  • Optical investigations

 

Indirect Additive Manufacturing (iAM)

  • Further development of the binder jetting process with regard to:
  • Suitability tests for molding materials, binders and different casting materials
  • Constructions suitable for cleaning
  • Automation solutions of the downstream processes for an economic mass production
 

Molding materials and inorganic binder systems

  • Research and testing of inorganically bonded sand binder systems for core shooting and indirect additive manufacturing
  • Materials testing: mechanical materials testing, temperature resistance and gas permeability measurements
 

Process Development

  • Simulations along the casting process chain
  • Prototype production in aluminum, copper and iron materials
  • Development of hybrid material composites
  • Value stream analysis
  • Process Data Management
  • Sensor technology for casting processes
  • AI models for casting use

New production methods in casting technology

Our research from start to finish along the process chain using the example of a battery tray with a cast-in bottom plate:

Voxel cast Bavaria

Bavaria 2.0: Scalable 3D model of the Munich Bavaria enables new milestone in Munich foundry technology

References

Casting

  • BMW AG
  • MWS Industrieholding GmbH
  • Pinter Guss GmbH
  • Brembo S.p.A.
  • NRU GmbH
  • Volkswagen AG

Casting supplier

  • FILL Gesellschaft m.b.H.
  • K + S Aktiengesellschaft
  • voxeljet AG
  • MEISSNER AG
  • Hüttenes-Albertus Chemische Werke GmbH

Other areas

  • AMK Holding GmbH & Co. KG
  • Robert Bosch GmbH
  • SIEMENS AG
  • Flow Science Deutschland GmbH
  • SANDHELDEN GMBH & CO. KG
  • Evum Motors GmbH
  • Feynsinn
  • EDAG Production Solutions GmbH & Co. KG

General Customer references Fraunhofer IGCV

About Fraunhofer IGCV

We are shaping the future of efficient engineering, networked production and intelligent multi-material solutions.

Industry Solutions and Services

The key sectors of Fraunhofer IGCV: Mechanical and plant engineering | Aerospace | Automotive

Cooperation with the Fraunhofer IGCV

We will be happy to find a customised solution for you.