Products & Solutions

Lightweight constructions save energy

The highly complex lightweight components are produced using four manufacturing technologies – from the development to the ready-to-mount solution.

The core competence is the development and the production of lightweight components in high-pressure die-casting, iron casting, precision casting as well as additive manufacturing. For years, research and development has been driven by efforts to lower CO2 emissions and to reduce vehicle weight.

 

Business Areas

First choice for castings & additive components

GF Casting Solutions is a technologically pioneering development partner and manufacturer of cast & additive manufactured components for the global automotive industry, aerospace and energy markets, off-highway vehicles as well as for industrial applications.

Global presence

GF Casting Solutions manufactures at 14 production sites in Germany, Austria, Romania, Switzerland, China and the USA. The research and development centers with globally recognized lightweight and bionic design expertise are located in Schaffhausen (Switzerland) and Suzhou (China).

GF Casting Solutions is the first choice for light vehicles, trucks, aerospace, energy, off-highway vehicles and industry applications. GF Casting Solutions is recognized for its development & production competence in aluminum & magnesium, iron and super alloys.

With the acquisition of the precision casting specialist GF Precicast in April 2018, the division not only extended its manufacturing competences but also achieved to diversify its market segmentation. With this fundamental strategic step, the division also received its new name GF Casting Solutions.

After the acquisition of two die-casting facilities in Romania in December 2017, GF Casting Solutions added new solutions within the industrial applications segment – such as lighting housings to its portfolio and extended its offer of components for passenger cars. The focus is not only on the high-pressure die-casting process, but also on the elaborate mechanical processing.

The new tool shop in Suzhou, China as well as our partnership with the leading mold maker GF meco eckel boosts the competitiveness of our light metal offering. The partnership with GF meco eckel will allow to earlier involve the component design, speed up the design-to-production processes, and ensure a seamless service for our customers.

In 2015, GF Casting Solutions announced a 50/50 joint venture with the world leading machining specialist Linamar Corp., Guelph (Ontario, Canada). Together, GF and Linamar Corp. invest in a new high-pressure die-casting plant in the Southeast of the US which was ceremoniously opened in October 2017.

Technologies

Expertise, innovation and quality

The Division compares materials and processes, determines key material data and tests components in its accredited lab. Thanks to the extensive development and production know-how, the development time between the prototype and the series product is significantly reduced.

Research & Development

Lightweight design is a hallmark of quality

Light components contribute actively towards the CO2 reduction. GF Casting Solutions develops casting processes for components that by means of lightweight design and downsizing reduce vehicle weight and thus also fuel consumption. By optimizing structures, GF Casting Solutions creates hollow, thin-walled castings with consistent or even better stability.

GF Casting Solutions has a strong focus on its central Research and Development department. Approximately three percent of annual revenue is spent on R&D.

References

Annual Report 2018: Success Story GF Casting Solutions

“We believe in continuous growth opportunities”

Doosan Heavy Industries (DHI) is a leading manufacturer of power generation equipment. In 2020, this South Korean company will bring its first in-house designed gas turbine to market. GF Precicast, part of GF Casting Solutions, is DHI’s strategic partner, equipping the turbine with heat-resistant precision-casting parts.

Audi A8 L

Lightweight design for the premium segment

Dynamic, safe and efficient: with the new A8, premium car manufacturer Audi has excelled itself in its core competence of lightweight design. For the car body, the so-called Audi Space Frame, GF Casting Solutions provides eleven ultra-light aluminum and magnesium castings – more than ever before. 

Volkswagen Teramont

Lightweight construction for a Chinese heavyweight

SAIC Volkswagen, a joint venture between the VW Group and SAIC Motor, is the leading car manufacturer in the world’s biggest automotive market China. Bionic lightweight construction components made by GF Casting Solutions have been used for years to reduce weight in these cars, including from 2017 in the new flagship SUV for the Chinese market.