Goldcasting Podcast

This Gold Nugget comes straight from the Euroguss show floor. Instead of a studio discussion, Fabian Niklas and Staffan Zetterström take the microphone into the exhibition halls and talk to people from across the entire value chain, OEMs, foundries, technology suppliers, alloy developers, associations, and young professionals.By stitching together many short conversations, this episode creates a realistic snapshot of how the industry feels right now: what’s driving optimism, where uncertainty remains, and which topics will matter most as we move into 2026.Interview Partners* Per Jansson from Comptech* Günther Prunner from voestalpine* Holger Wagner from KMA Umwelttechnik* Tao Wang from PSW Group* Tuncag Cihangir Sen from the Turkish Foundry Association* Natrayan Nagamuthu from Comptech* Chris Sleath from Spartan Light Metal Products* Michael Klein from Ford Motors* Paul Becker from GTK“Start to do something. Develop your business. Grow your business.”What makes this episode special is its diversity of perspectives. Different regions, different roles, different levels of experience, but a surprisingly consistent conclusion. The industry is under pressure, yes, but it is also full of ideas, energy, and opportunity for those willing to act.Euroguss shows that the future won’t be shaped by waiting for better conditions. It will be shaped by companies and individuals who invest, adapt, collaborate, and position themselves clearly.If you want to understand how the industry sees itself heading into 2026, this episode is worth listening to all the way to the end.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, write comments, or make suggestions for future episodes.Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

2025 tested the foundry industry like it hasn't in many years. Volumes dropped, forecasts evaporated, and many companies found themselves stuck between rising costs and shrinking demand. In this Gold Nugget, Fabian Niklas and Staffan Zetterström reflect on what really went wrong in 2025 and why 2026 will be the year that separates those who merely survive from those who actively shape their future.This conversation is about decision-making, responsibility, and positioning. Not waiting for OEMs. Not hoping for better portals. But deliberately preparing, technically, strategically, and personally, to look back at the end of 2026 and say: That was a turning point.Key Topics* 2026 as the decision year: Why overcapacity, consolidation, and bankruptcies will force hard choices and why hesitation may be the most dangerous strategy of all.* Where real opportunities are emerging in casting: Beyond the gigacasting headlines, the discussion explores why certain machine sizes, alloys, and applications are quietly gaining traction and why margins won’t come from where everyone is looking.* The return of metallurgy as a profit driver: Sustainability, alloy flexibility, scrap usage, and property optimization are no longer “nice to have.” They are becoming decisive competitive factors.* Why branding is no longer optional: From company brands to personal brands, visibility and trust are shaping who gets invited into new developments and who remains just another line in a comparison sheet.* How software, data, and new roles change the game: As process windows shrink and complexity rises, the episode dives into why software, knowledge capture, and interdisciplinary thinking will define efficient production going forward.* Why Asia will matter more than ever: A clear-eyed look at where growth, investment, and experimentation are accelerating and what that means for European foundries and professionals.“Waiting for portals and RFQs is no longer a strategy; owning your future is.”One theme runs through the entire episode: ownership. Ownership of knowledge. Ownership of decisions. Ownership of visibility. The industry is moving away from one-size-fits-all alloys, static specifications, and passive supplier roles. In their place come specialization, branding, smarter processes, and people willing to learn fast and act early.2026 won’t be easy, but for those who invest in skills, systems, and credibility now, it can become a defining year. This episode is both a reality check and a call to action for anyone who wants to be relevant, profitable, and future-proof in the foundry industry.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, write comments, or make suggestions for future episodes.We hope to meet you at the Euroguss!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

Staffan Zetterström and Fabian Niklas invite you on a Euroguss tour built around the people and companies who have appeared on the Goldcasting Podcast. These are the companies that dared to step outside the box, share insights openly, and contribute to shaping the future of casting.This episode is about energy, ideas, and conversations. Use it as your personal map through Euroguss to meet people who think differently and are happy to continue the discussion face-to-face at their booths. Use the podcast as a conversation starter, tell them you came via the Goldcasting Podcast.Also, your hosts are present at the Euroguss with booths. You’ll find Staffan at the Comptech booth and Fabian at the Casting-Campus booth.Companies on the Euroguss Tour* 7A-110 Chem-Trend with Darko Tomazic (GN 37 - Spray your Production Issues away with HERA)* 7A-420 Grob with Carsten König (GN 36 - The Essence of Employer Branding for the Foundry Industry)* 7-524 Rockman with Tej Bambra (GN 56 - The Indian Market for Die-Castings)* 7-132 Stena Aluminium with Erik Petre (GN 21 - The Kings of Scrap)* 5-214 voestalpine with Dr. Armin Wiedenegger (GN 22 - How to increase the Tool Lifetime of Gigacastings)* 5-246 Euroguss with Christopher Boss (GN 45 - The Euroguss Executive Circle)* 5-250e University of Kassel with Prof. Fehlbier (GN41 - The First Global GIGA-Casting Congress)* 5-468 Laubinger + Rickmann with Philipp Hettich (GN 19 - Geometric Distortion of Gigacastings)* 5-162a Dynatool Industries with JC Tawil (GN 16 - Maple Syrup on the US Market with Jean-Claude Tawil)* 5-162d Comptech with Dr. Per Jansson (GN 9 - Dr. Per Jansson changes the World one Slurry at a Time; GN 18 - Is Rheocasting the Savior of Gigacasting?; GN 54 - The Opportunities Rheocasting creates for Foundries, GN 59 - Software to prove the Stability of Rheocasting)* 5-162f Spartan Light Metal Products with Chris Sleath and Scott Meyer (GN 48 - Rheocasting Developments at Spartan)* 5-153 Casting-Campus with Fabian Niklas (GN 55 - Content Marketing for the Foundry Industry; GN 57 - Learn how to implement Rheocasting profitably)* 4-168 Gnutti Carlo Group with Eric Müller (GN 38 - The Future of the Die-Casting Industry is Marketing)* 4-348 Teraport with Raphael Heilig (GN 40 - A joint HPDC Industry in Europe as a Best Seller)* 4-342 Magma Gießereitechnologie with Dr. Horst Bramann (GN 46 - Risk Mitigation in Gigacasting with MAGMASOFT)* 4-340 ItalPresseGauss with Peter Sell (GN 24 - The Race to the highest Clamping Force)* 4A-216 Bühler with Dr. Markus Hofer (GN 25 - How the Merger of Disciplines makes Casting successful)* 4A-114 Handtmann with Andreas Würzer (GN 50 - German Megacasting and Chinese Speed)* 4A-314 Heck + Becker with Benni Jung and Andre Weißbrenner (GN 7 - The Transformation of Heck + Becker, GN 33 - Leveraging of Cooperation takes off at the Euroguss Executive Circle)Want to Be on the Next Tour?If you feel your company should be part of a future Goldcasting tour, talk to us.Stop by at Euroguss, give us a call, or reach out after the show. Let’s discuss how your story could be featured on the podcast and maybe on the next tour map.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, write comments, or make suggestions for future episodes.We hope to meet you at the Euroguss!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

The Rheowalk is an initiative to showcase a worldwide network supporting Rheocasting, organized by Comptech. This Gold Nugget is based on this map and provides additional insights into why you should visit each company.You will find Staffan Zetterström at the Comptech booth (5-162d) and Fabian Niklas at the Casting-Campus booth (5-153). Both hosts are proud to share each company's Rheocasting accomplishments with you. Following the steps in this tour, you can see, learn, and discuss with these experts, who can present the interesting aspects of Rheocasting. When you enter the Euroguss trade fair, turn left and start in hall 4A, or invert the list when you want to start in hall 7A.Companies in the Rheowalk4A-216: Bühler4A-322: Wieland Caro4A-522: Faist Light Metals4-342: Magma4-116: DGS5-153: Casting-Campus5-162d: Comptech5-162f: Spartan Light Metal Products5-162a: Dynatool Industries5-162b: PSW Group5-162g: PTS Prüftechnik5-162c: G-Plast5-361: Millison Technologies5-250a: Österreichisches Gießereiinstitut (ÖGI)5-250e: Gießerei Technik Kassel (GTK)7-132: Stena Aluminium7A-110: Chem-TrendSee you in Nürnberg!Follow along the Rheowalk and become a Rheocasting insider as well. Use the podcast as a conversation starter at the booths and talk to our friends, partners, and colleagues. We are all looking forward to talking to you about our favorite topic - Rheocasting!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, write comments, or make suggestions for future episodes.We hope to meet you at the Euroguss!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

For decades, process stability in semi-solid casting has been the single biggest barrier to scaling the technology. With automotive quality departments demanding verifiable, traceable, and reproducible solid-fraction data, the days of “trust us, we’ve done 5,000 quenches” are over.In this sponsored episode, Fabian Niklas interviews Staffan Zetterström, not as co-host, but as Marketing & Sales Manager of Comptech Rheocasting, to reveal a quiet revolution. A new solid-fraction analysis software developed jointly with academia and powered by machine learning.It’s a candid look at why an equipment manufacturer took the leap into software, what it actually solves for foundries, and what this signals for the future of process control, gigacastings, and data-driven casting development.Key Insights* You cannot scale semi-solid casting without proving your solid fractionAutomotive OEMs are increasingly asking two questions: Is your process stable? And what solid fraction do you have? Without hard data, foundries won’t pass nomination gates, no matter how good their slurry looks on paper.* Machine learning + metallurgy = a breakthrough in usabilityThe software automatically analyzes microstructures using models trained in collaboration with leading researchers at Jönköping University. Customers simply upload a polished sample; Comptech validates the rest. The approach blends advanced algorithms with decades of metallurgical expertise to deliver numbers engineers can trust.* Foundries need digital tools because casting leaves zero margin for errorProducing a rear floor, battery tray, or front cradle every 60 seconds means any alloy mis-specification or solid-fraction drift multiplies into catastrophic cost and unmanageable recalls.Software-based validation is quickly becoming a necessity, not a luxury, for gigacasting programs. The amount of data required for optimization simply cannot be handled manually.* Building software as a hardware company is messy, but necessaryComptech openly shares how challenging it was for a traditional hardware-focused organization to create software. Translating academic research into a tool that can be used at 3:15 in the morning on the shop floor required a complete shift in mindset. The team had to rethink manuals, user flows, pricing, packaging, and even internal processes such as accounting and distribution.“Would we do it again? Absolutely!”Despite the cost, uncertainty, and growing pains, Comptech says developing this software was essential. It solves a foundational problem, enables more machine sales, unlocks validation for customers, and prepares the industry for the next era of data-driven casting development.Software is no longer optional — it’s the next strategic layer of competitiveness.Whether you’re an equipment supplier, foundry manager, quality engineer, or casting developer, this episode shows how digital tools are becoming essential to winning nominations, qualifying parts, and securing the next generation of high-value casting programs.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, write comments, or make suggestions for future episodes.Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

Staffan Zetterström and Fabian Niklas break down why the future of the foundry industry cannot rely on automotive alone and why non-automotive business is rapidly becoming the most strategic and profitable path forward.With automotive volumes flattening, EV architectures reducing part count, and new competitors squeezing margins, the classic “wait for the rebound” mindset is no longer viable. This episode explains what is changing, which industries offer real opportunities, and what foundries must rethink to reach customers who don’t traditionally work with castings.Whether you’re a foundry owner, commercial leader, or technical manager, this discussion provides a practical roadmap for expanding into new markets, building resilience, and taking control of your long-term business development.Key Insights* New industries are opening up, if you know where to lookSome sectors outside the automotive industry are quietly becoming gold mines for foundries. The opportunities are bigger than most expect.* These customers don’t think like automotive, and that’s the advantageWhen the purchasing logic changes, so does the way you win business. The rules are different and far more favorable for those who adapt.* Speed matters more than you think!In specific industries, your response time can outweigh your price. A simple shift in pace can unlock doors that were previously closed.* The casting is only the beginningIn many applications, the casting itself is a small part of the total value. Knowing how the rest of the product comes together makes all the difference.* Marketing becomes your new inbound engineTo get in front of industries that don’t know you, and don’t know they need you, communication becomes a strategic capability, not a nice-to-have.* Visibility beats perfectionYou don’t need millions of views. You need the right 10–14 people to see you, recognize you, and start a conversation. Being present in the right channels makes that happen.“You’re not selling a 1,99€ lipstick; you’re selling trust!”This episode highlights why diversifying beyond automotive isn’t optional anymore. It’s a strategic move that can unlock long-lived programs, higher margins, closer customer relationships, and a more stable future, but only if foundries build the commercial muscles needed to reach industries that operate very differently from the automotive industry.Rather than waiting for the market to recover, this Gold Nugget outlines how to create your own demand, position your expertise, and win business in sectors that value engineering service, reliability, and sustainability.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, write comments, or make suggestions for future episodes.Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

Staffan Zetterström and Fabian Niklas take a closer look at the Rheocasting Masterclass by Casting-Campus GmbH. A practical, business-focused online learning format designed to help the foundry industry unlock new applications and profits with Rheocasting.Whether you’re an engineer evaluating new processes, a commercial leader searching for fresh revenue streams, or a supplier who wants to understand where the industry is heading, this podcast provides a clear view of why Rheocasting is gaining traction now and how the proper knowledge can unlock an unfair advantage for anyone ready to move first.Key Insights* What the Masterclass covers: From solidification and rheological behavior to business development, application design, and market positioning.* Lower alloy silicon ≠ lower opportunity: How Rheocasting compensates for castability challenges in giga- and megacastings, while improving tool life and performance.* New applications advantage: Conductivity jumps from ~140 W/mK to nearly 200 W/mK with low-Si alloys, enabling new electronics and cooling concepts.* Who’s joining?: Strong participation from Italy, the U.S., and India, with foundries, suppliers, and OEMs unified in the need to understand Rheocasting.* Flexible global access: Six webinars, multiple meetings for different time zones, and a format that works for operators, engineers, sales teams, and management alike.* Business first: Rheocasting success requires marketing, design collaboration, and early customer involvement; not just buying new equipment.“Buying the machine is the easy part, the value is created when you build new business with it.”This episode highlights how rising demand for high-performance components, shrinking automotive volumes, and the push for differentiation make Rheocasting a timely strategic move for foundries. With a format that is affordable, accessible, and designed for real-world implementation, the Masterclass aims to close the gap between technical capability and profitable business execution. It empowers foundries not just to make better parts, but to win new applications, build stronger customer relationships, and take control of their future in a rapidly changing market.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, write comments, or make suggestions for future episodes.Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

In this episode, Staffan Zetterström and Fabian Niklas travel to India, one of the world's most dynamic and rapidly growing die casting markets. Our guest, Tej Bambra, brings nearly four decades of industry experience and a lifetime of insight into how the Indian die casting landscape has evolved from manual casting in the 1970s to today’s robotics and closed-loop systems.Key Insights* India vs. China — how scale, demand, and government incentives shape both markets.* Technology adoption — why most Indian die casters still rely on imported European and Chinese machinery, and how this affects cost competitiveness.* Materials and innovation — the early steps in magnesium die casting and the maturity of aluminium smelting in India.* Automotive outlook — from 4.9 million four-wheelers and 21 million two-wheelers today to a projected 10 million cars by 2030.* EV growth and the two-wheeler backbone — how electrification could reshape India’s mobility sector.* Global positioning — what it will take for India to narrow the gap to China and become a true manufacturing counterweight.“The Future is bright, but we have to bridge the Gap in Technology and Scale”Tej also reflects on the cultural and economic contrasts between Europe and India: while the West may be moving away from car ownership, in India, a car remains a symbol of status and freedom, and that demand is driving industrial growth.This episode offers a grounded look at where Indian die casting stands today and how it’s preparing for the next decade of transformation.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, write comments, or make suggestions for future episodes.Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

This week, Staffan Zetterström sits down with Fabian Niklas, this time in a different role. Fabian is the driving force behind the new Marketing Accelerator for the high-pressure die casting industry.If you’ve ever struggled to make your company visible beyond job ads and trade fairs, this episode is for you. Fabian explains why our industry has world-class technology but often hides it “in the drawer”, how to finally communicate benefits (not just features), and why consistent, smart content will attract the right customers and even AI search engines to your doorstep.Key Insights* Why great die casting innovations often remain invisible, and how to change that.* How the Marketing Accelerator works: bi-weekly online meetups, peer feedback, and content accountability.* Turning content into real leads and why mass press releases don’t work on Social Media.* How AI search is changing how buyers find foundries and how to be discoverable.* The power of consistency and uniqueness in technical B2B marketing.* Building a personal brand that moves with you throughout your career.Either you die a little bit every day, or you develop a little bit every dayWhether you’re responsible for business development, employer branding, or just curious about building your personal brand in die casting, the Marketing Accelerator is a free, community-driven workshop to learn, share, and grow. Invest a few hours, try the Marketing Accelerator, and see where it takes you.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, write comments, or make suggestions for future episodes.Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

Too much idle capacity, not enough profitable work? This episode is your field guide. Staffan Zetterström and Fabian Niklas welcome Dr. Per Jansson of Comptech (one of our sponsors) to map the fastest paths from Rheocasting theory to booked orders, as well as the small process tweaks that make buyers say “yes” to trials.Key Insights* From buzzword to backlog: How a few smart Rheocasting moves can turn idle capacity into booked work.* Easy entry points: Where you can start with existing parts and alloys yet unlock fewer leaks, less porosity, and longer tool lifetimes.* Heat Management is the new volume: Why thermal management parts are an overlooked market and what Rheocasting changes about fin height and thickness.* Gigacasting productivity mindset: Where big structural ambitions meet gentler fill and why that combo matters for ductility and joining technologies.* Winning the RFQ before it’s an RFQ: The positioning and proof steps that get buyers to say “yes” to a trial and come back for a program.* Outlook by region: Who’s moving first and why; a quick tour across Japan & Korea, China, India, North America, and Europe.Foundries need a new Playbook now!If you’re staring at idle capacity, leaky problem parts, or RFQs that only talk price, this episode is your nudge to try something different. Start small, prove fast, and turn one stubborn part into the pilot that changes your pipeline.Listen in for the “start on Monday” version of Rheocasting: where to begin without redraws, how to frame a low-risk trial, and which markets are buying right now.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, write comments, or make suggestions for future episodes.Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

This episode takes you far east into China. Staffan Zetterström and Fabian Niklas sit down with Tracy Feng, a long-time insider of the Chinese die-casting industry. From Shanghai, she brings a unique perspective on how the world’s largest automotive and die-casting market is evolving and what makes it so different from Europe.Key Insights* Gigacasting in China: while Europe still debates, Chinese OEMs are already in mass production and moving to the next challenge.* The rise of magnesium & thixomolding: why these technologies are gaining momentum and what makes China a hotspot for innovation.* Collaboration culture: how automakers, suppliers, universities, and machine builders work together and why that accelerates change.* China’s speed advantage: what drives the rapid adoption of new technologies and the sheer pace of industrial transformation.* Global ambitions: why Chinese die casters and automakers are looking beyond their home market, and what that could mean for Europe.* Beyond automotive: how applications in robotics, drones, 6G, and new mobility forms are reshaping the die-casting landscape.Learn about the Next Wave in ChinaTracy’s insider view reveals not just where China is today, but where it’s heading, and why it matters for anyone in the global die-casting and foundry industry. Don’t miss this unique glimpse behind the curtain of the Chinese market, full of lessons, surprises, and signals for the future.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, write comments, or make suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

We all heard the news about the current situation of the European automotive market. Staffan Zetterström and Fabian Niklas unpack the latest data and trends shaping the European automotive landscape based on the published quarterly reports of the OEMs. With sales results in, shifting consumer behaviour, and new players rising, the picture is far from simple.Key Takeaways:* Sales Numbers under the Microscope:What do the most recent OEM results tell us? Revenues, profits, and volumes all point in different directions, and the implications run deep.* The Distribution Story:From small cars to premium EVs and SUVs, the mix of what people are buying in Europe is changing. But are we moving as fast as we think?* The Chinese Acceleration:Chinese carmakers are gaining ground at record speed. How significant is their presence in Europe today, and how disruptive could it become tomorrow?* The Foundry Industry Impact:Automotive shifts ripple straight into the foundry world. Which trends will squeeze suppliers hardest, and which could open unexpected doors?* The Way Forward:With pressure on all sides, what strategies are left for foundries and suppliers to not only survive, but thrive?Listen closely and get a head start!The European automotive industry is in a state of flux, and that matters because automotive is still the foundry industry’s single biggest customer. If your business depends on supplying the automotive sector, these insights aren’t optional; they’re survival material. Listen to Gold Nugget 52 and start the implementation process.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, write comments, or make suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

In this nearly detective-style episode, Fabian Niklas and Staffan Zetterström break from opinion and prediction to bring you something else entirely:data. Open source, fact-based insights that paint a sobering picture of where the die-casting market is headed and what every foundry leader needs to understand.Key Takeaways:* The Global Car Market Is ShiftingFrom 2014 to today, the production landscape has changed dramatically. Europe is no longer holding its ground, while China continues to accelerate. Despite some forecasts predicting smooth growth, a closer look reveals regional divergence that shouldn't be ignored.* The EV EffectThe industry’s dependence on combustion engines is rapidly becoming a liability. EVs require fewer cast components, fewer shots, and radically different platforms. In the space of just five years, the average number of casting shots per car is expected to drop dramatically, even as total vehicle output grows.* Why This MattersIt’s not just about fewer castings. It’s about platform shifts, software priorities, changing consumer preferences, and new forms of transportation entirely. From software-defined vehicles to new ownership models, foundries must adapt to an industry where value creation has moved elsewhere.* A Calculated Wake-Up CallWe’ve combined four critical data points to arrive at a clear message: the future volume of casting shots is under direct threat. Even in optimistic scenarios, the number of available projects is falling, and with it, the economic foundation of many foundries.Your Input is Welcome!This report isn’t the final word – it’s the beginning of a conversation. We invite you to challenge the assumptions, question the calculations, and contribute your insights. Regional deep-dives are already in the works, beginning with Europe.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, write comments, or make suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

In this milestone 50th episode of Goldcasting, your hosts, Staffan Zetterström and Fabian Niklas, welcome Andreas Würzer from Handtmann, one of the few companies in Europe pushing megacasting forward with full force. While the rest of the world watches China sprint through the gigacasting evolution, Handtmann has already hit the ground running, without even waiting for a customer nomination.Key Takeaways:* A Strategic Gamble with Gigacasting in GermanyHandtmann invested in gigacasting before landing a contract. Why? Strategic foresight, market studies, and a commitment to pushing development, not waiting for it.* Chinese Speed vs. German LegacyEurope’s brownfield limitations contrast with China’s greenfield advantage. Andreas Würzer explains why this slows down OEMs in Germany and what needs to change.* Engineering as a DifferentiatorHandtmann hasn’t just bought a machine; they’re building capabilities. Simulation, topology optimisation, validation, and even additive manufacturing are baked into their development DNA.* From Brochure to Business CaseAndreas Würzer shares what it really takes to convince OEMs. It is not PowerPoint presentations, but functional prototypes, real-world testing, and co-developed design spaces.* Material MattersHandtmann is advancing the use of secondary alloys, even in structural parts, and views semi-solid casting as a productivity booster, particularly at lower temperatures, with improved flow and reduced wear.* The Long ViewThis isn’t a one-shot bet. Andreas Würzer sees megacasting as entering its first evolutionary step in Europe. The real transformation is yet to come with better alloys, lighter walls, and smarter integration.If you're waiting for the OEM, you're too late!If you're serious about the future of casting, this episode is a blueprint for how to lead and take responsibility in a fast-changing industry. Tune in now. Learn from those who don’t wait for an OEM to make a decision, but instead take the initiative and do the groundwork themselves.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, write comments, or make suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

In Gold Nugget 49, Staffan Zetterström and Fabian Niklas take a hard look at the economic storm shaking the global die-casting sector. From bankruptcies in Germany to collapsing volumes in Europe and the brutal rise of EVs, no region or supplier is untouched.Why are even the “big” foundries going under? What’s behind the silence from OEMs who once sent in rescue teams? And most importantly, what can be done now to survive?Key Takeaways:* The Foundry Industry Is in a Financial FreefallWith bankruptcies affecting big names like AE Group and Trimet Bohai, it’s clear this isn’t just a small foundry problem. The entire sector is under pressure, and OEMs are moving quickly to protect their supply chains, often by abandoning suppliers that are struggling.* Car Production Has Dropped by Half in EuropeBetween 2022 and 2025, European car production is down by 50%. EVs are accelerating this decline in volume per casting, replacing complex multi-part combustion designs with fewer, larger, and heavier castings.* Nobody Wants to Own a FoundryLarge corporations are spinning off their casting divisions, and investors are staying away. Why? Die casting is no longer seen as a future-facing technology by many boardrooms. Even successful foundries are being split off, sold, or liquidated.* OEMs Now Prioritize ‘Safe Harbor’ Over LoyaltyGone are the days when OEMs sent in rescue teams. Today, they quickly pull tools from troubled suppliers and move them to more stable partners, often without a second chance: short fuses, fast decisions, and no second chances.* Overcapacity + Automation = TroubleAutomated lines are only effective at high volumes. However, with shrinking order books, many foundries are now left with expensive, inflexible equipment and insufficient parts to operate it.Take Action or Be Left BehindListen to GN49 to understand how the financial crisis is reshaping the casting world and what it takes to survive. It’s a wake-up call for foundry owners, engineers, and decision-makers across the value chain.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, write comments, or make suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

In Gold Nugget 48, we welcome Chris Sleath and Scott Meyer from Spartan Light Metals Inc., who sponsored this episode. Spartan is a U.S.-based die caster that’s making serious waves with its investment in Rheocasting technology. Spartan was the first company in the USA to implement the Comptech slurry maker, and over the past two years, they’ve shifted from being a traditional powertrain supplier to an R&D-driven structural casting innovator.Together with hosts Fabian Niklas and Staffan Zetterström, Chris and Scott share what it takes to introduce new processes, rethink old assumptions, and bring advanced aluminium solutions to market in a highly competitive space.Key Takeaways:* Spartan is leading Rheocasting in the U.S.Spartan Light Metals is the first company in the United States to install and run a Comptech slurry maker. They’re not just testing Rheocasting, they’re scaling it.* From powertrain to structural castingsTraditionally focused on drivetrain housings, Spartan is now moving aggressively into structural parts. Their R&D efforts are focused on helping OEMs design lighter, stronger components for next-generation EV platforms.* It’s not just about tech—it’s about approachInstead of chasing headlines, Spartan is taking a methodical, engineering-first route. By modifying existing HPDC tools and integrating Rheocasting without disrupting production, they’re showing how to do it the right way.* More die life, less porosity, better partsCustomers are already seeing the benefits: longer die life, improved flow lengths, and cleaner parts with less gas entrapment. Rheocasting is proving itself on the shop floor, not just in PowerPoints.* Global partnerships for a global footprintThrough a new alliance with KS Huayu Alutech, Spartan can now support programs across North America, Europe, and Asia. One design, one partner, global delivery.* Sustainability with a business caseRheocasting uses less energy and generates less scrap. Spartan is pushing toward carbon goals not because of regulation, but because it makes economic sense.Technology leadership, not just slogans.What emerges from this conversation is a clear picture of a company that knows who it is and where it’s going. With a deep commitment to engineering, Spartan is building a bridge between legacy know-how and next-generation manufacturing, with Rheocasting as a central pillar.And yes, they’ll be at Euroguss 2026 in Nuremberg. If you’re curious about Rheocasting, structural die casting, or just want to meet the people behind the "space trumpet," make sure to stop by their booth; Saint Kevin (and a cold beer) will be waiting.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, write comments, or make suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

In episode 47 of the Goldcasting Podcast, Fabian Niklas and Staffan Zetterström travel east, all the way to the world’s largest foundry economy: China. Joining them are two voices from the Chinese casting industry: Ms. Lindsay Bao from FICMES and Dr. Jerry Sun, CEO of CASFU.Together, they dive into the booming Chinese EV market, the magnesium revolution, and the rapid rise of gigacasting in Asia. But more importantly, they explain why China Die Casting, taking place this July 16–18 in Shanghai, is the global hotspot for anyone serious about casting.Whether you’re an OEM, Tier 1, tech supplier, or materials specialist, if you're looking for the future of die casting, this is the place to be.Key Takeaways:* It’s the biggest die-casting show in the worldWith over 560 exhibitors, 20,000 expected visitors, and 49,200 m² of show space, China Die Casting 2025 is the largest and most dynamic die casting exhibition globally.* Live machines, not PowerPointsEach year, 15–20 high-pressure die-casting machines run live on the floor. If you want to crawl around real gigacasting equipment, this is your chance.* China is the Epicenter of Gigacasting80% of global gigacasting machines are being installed in China. Tesla started the revolution, but Chinese EV makers are scaling it. From Xiaomi to NIO, they’re already on their 10th iteration and beyond.* Magnesium is here to stayChina holds over 60% of the world’s magnesium resources, and now it’s leading the charge in magnesium gigacasting. If you're looking to lightweight your components, this is where the action is.* Semi-solid, squeeze casting, low-pressure die-casting – it's all thereThe show goes beyond traditional HPDC. Whether you're into Rheocasting, thixocasting, or new alloy developments, expect to see it in action and meet the people behind it.* Full production chain under one roofFrom simulation software to melting tech, machining, and heat treatment, you’ll find every piece of the puzzle.* It’s the center of the casting worldShanghai isn’t just a vibrant, modern city – it’s where casting innovation is accelerating the fastest. Come for the tech, stay for the food and business matchmaking.Join us in Shanghai – July 16–18, 2025Meet the pioneers. See the machines. Experience the future. China Die Casting – don’t miss 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, write comments, or make suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

In Gold Nugget 46, which MAGMASOFT sponsored, your hosts, Staffan Zetterström and Fabian Niklas, are joined by Dr. Horst Bramann from Magma to dive into how advanced casting simulation is revolutionising risk mitigation, sustainability, and digital transformation in the foundry industry.Key Takeaways:* DOE-Driven Simulation: Horst walks through Magma’s Design of Experiments approach, showing how running multiple gating layouts and process parameters in one project yields statistically robust insights for defect prevention and tool longevity.* Front-Loading Sustainability & Cost: The new Magma Economics modules embed cost and CO₂ footprint assessments directly into early‐stage simulation, aligning quality metrics with environmental and financial targets.* From Virtual to Reality: Global support via Magma Academy, Magma Interact data sharing, and integration with FE tools create a closed‐loop between simulation and production—feeding measured results back into continuous improvement.* Autonomous Engineering & AI: Parametric geometry libraries and AI-driven assistants are already automating gating and overflow design, paving the way for next-gen topology optimisation and truly autonomous foundry engineering.Tune In Now:Discover how Magma’s cutting-edge simulation modules and training programs are empowering foundries to tackle EV-driven challenges, gigacasting risks, and sustainability goals, all before a single mould is cut. Subscribe to the Goldcasting Podcast on your favourite platform and listen to the episode for a forward-looking blueprint on digitalising your foundry.Thank you for listening, and 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, write comments, or make suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

In Gold Nugget 45, which Euroguss sponsored, your hosts Staffan Zetterström and Fabian Niklas are joined by Christoph Boss, the mastermind behind Euroguss’s transformation into a year-round platform for innovation and industry dialogue. The episode focuses on the Euroguss Executive Circle, a top-level forum for strategic collaboration among European die-casting leaders.Key Takeaways:* Christoph explains how Euroguss evolved beyond its roots as an exhibition organiser. It now functions as a full-year engagement platform called Euroguss 365, enabling continuous content creation, networking, and strategic marketing for the die casting industry.* The Executive Circle is a unique forum where C-level leaders across the European die casting value chain can connect, collaborate, and explore the industry's long-term future beyond day-to-day operations. * The discussion reflects on key issues tackled during previous Executive Circles, including the importance of cooperation across the supply chain, modernising employer branding to attract new talent, and harnessing digitalisation and AI to boost competitiveness.* The next edition of the Executive Circle, taking place in Northern Italy, will feature hands-on workshops on AI, marketing, and talent acquisition, along with keynotes by Professor Dudenhöffer and others. The event will be interactive, discussion-led, and impactful for strategic planning.Tune In Now:The third Executive Circle will take place in Milano, a region deeply connected to die casting. The location was chosen not just for its industrial relevance, but also to reinforce the European and collaborative nature of the event. Before that event starts in July, subscribe to the Goldcasting Podcast and listen through the Euroguss Executive Circle Series.Thank you for listening, and 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, write comments, or make suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com

In this thought-provoking episode, Staffan and Fabian dig into a critical question that’s quietly gaining traction in the foundry world: Are we witnessing the rise and potential burst of a Gigacasting bubble? With massive investments pouring into ever-larger die-casting machines and new OEMs popping up by the dozen, the landscape looks both exciting and risky. Is the industry scaling too fast, too soon?What’s inside this episode?* An overview of the current Gigacasting machine landscape across North America, Europe, and China, including how many are running, idle, or still being installed* The economics of Gigacasting: how part reduction, weight savings, and cost improvements compare to conventional manufacturing* Why the OEM model in China, especially the "shop-in-shop" setup is creating capacity bottlenecks and utilization challenges* How global macroeconomic pressures like rising interest rates, oversupply, and political instability could trigger a correction* The implications of a potential shakeout: which players might falter, and why knowledge, adaptability, and scale will matter more than ever* What a reset in expectations could mean for casting technology, machine sizing, engineering focus, and strategic investment, especially in EuropeGet Involved:Do you see the early signs of a bubble, or are we just entering a new phase of maturity in Gigacasting? Share your view in the comments—or better yet, join us for a future episode.Thank you for listening, and 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, write comments, or make suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com