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 Behind

Listen 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

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

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, 2025

Meet 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