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

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

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

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 Europe

Get 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

In Gold Nugget No. 43 of the Goldcasting Podcast, we explore the changing dynamics between OEMs and their supply networks based on the discussions at the Euroguss Executive Circle, which also sponsored this episode. Hosted by Fabian Niklas and Staffan Zetterström, this conversation features special guest Katrin Grebe, Managing Director at Krämer & Grebe, a German toolmaking company.

Together, they unpack the urgent need for stronger collaboration across the entire automotive value chain. They also explore how foundries, toolmakers, and other suppliers can unlock speed, efficiency, and innovation if OEMs are willing to embrace change.

What’s inside this episode?

* Why early supplier involvement ("front-loading") is a game-changer for product development

* The growing gap in casting knowledge inside OEMs and how suppliers are filling it

* How rigid departmental silos and outdated purchasing models are slowing down Europe’s automotive sector

* The dangers of focusing solely on upfront costs instead of Total Cost of Ownership (TCO)

* How Asian and U.S. OEMs are outpacing Europe through agile, collaborative partnerships

* Why cultural transformation and strategic lobbying are vital for Europe’s competitive survival

Get Involved:

The European automotive industry is at a crossroads. Embracing supplier collaboration isn’t optional—it’s essential for speed, sustainability, and survival in a highly competitive global market.

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

The missing volumes are the largest problem for most foundries worldwide. In this episode of Goldcasting Podcast, your hosts Staffan Zetterström and Fabian Niklas dive into the exciting world of new business opportunities. Reflecting on predictions made in past episodes, the duo highlights real-world applications that are now gaining traction. From CO₂-based climate systems to telecom heat sinks and sustainable castings, this Gold Nugget offers practical insights into future-proof markets actively generating RFQs and nominations.

What’s inside this episode?

* CO₂ Climate Systems – A Market Heating UpWith the EU’s F-Gas ban taking effect, automotive OEMs are shifting to CO₂-based air conditioning systems. Staffan and Fabian explain why these parts require innovative casting approaches, like Rheocasting, to meet the high-pressure and high-temperature demands.

* Telecom and Thermal Management – Ready to Scale Now5G and data infrastructure create massive demand for high-conductivity heat sinks. Foundries can benefit from telecom’s rapid timelines, where design cycles are short and production ramps up quickly.

* Automotive E-Boxes and Beyond – Not Just EVs AnymoreWhile much of the die-casting buzz has been around gigacastings, the real opportunity lies in electronic enclosures, powertrain cooling, and battery thermal systems.

* Sustainable Castings – A Purchasing Requirement, Not a BonusSustainability is becoming a hard requirement. Sectors like telecom and medical are leading the charge, often paying a premium for sustainable castings.

* Exporting to Europe – A Hidden OpportunityFor non-European foundries, the upcoming CBAM regulation might seem like a threat, but it’s actually a strategic opportunity and can serve as a USP in an increasingly regulated market.

Get Involved:

Most of these opportunities won’t be found on online portals. Success comes from proactive marketing, engaging with new customers early, and adapting to industries outside the traditional automotive world. Whether it’s telecom, medical, industrial lighting, or emerging EV components, the future of die casting lies in innovation, speed, and strategic positioning. Don’t miss this episode if you want new markets with margin-friendly parts.

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