Goldcasting Podcast

AI is no longer something the foundry industry can laugh off as a distant software trend. Large language models are already being used by engineers, buyers, designers, and decision-makers to explore manufacturing options, compare processes, prepare for meetings, and form first impressions of suppliers.In this episode, Fabian Niklas and Staffan Zetterström look at AI from the perspective of foundry guys, not AI experts. The central concern is not that LLMs (Large Language Models) exist. The real problem is that LLMs often provide poor or outdated answers about casting because the foundry industry has not produced enough accessible, up-to-date, publicly available information for these systems to learn from.That has direct commercial consequences. If an engineer, product designer, or purchasing team asks an LLM whether a part should be cast, the answer may be shaped by outdated textbook assumptions rather than by modern high-pressure die-casting practices. In the worst case, AI does not just misunderstand casting, it quietly sends potential customers somewhere else.The episode is a grounded conversation about what AI can do, where it fails, and why foundries should start testing it from the perspective of their target customers.Key Topics* Why AI drives customers away from castingWhen an engineer asks an LLM for manufacturing advice, the answer depends on the information available online. If current casting knowledge and marketing material are missing, the model may recommend against casting based on outdated assumptions.* The foundry industry has a visibility problemAI often fails to distinguish between older textbook descriptions and modern die-casting processes. The issue is not only technical accuracy but also the lack of publicly searchable material showing what today’s foundries can actually do.* Try AI Seach from your customer’s perspectiveAsk the same questions your target customers would ask. Search for your process, your applications, your company, and your alternatives and then see whether AI leads people toward your capabilities or away from them.* AI is useful, but only with the right inputLLMs depend heavily on the quality of the question, the available data, and the user’s ability to judge the answer. It can produce convincing text even when the technical conclusion is weak or incomplete.* Marketing cannot be fully outsourced to AIAI can help organize, draft, and accelerate communication, but it cannot replace a company’s identity, technical judgment, or real application knowledge. If a foundry uses AI to create marketing without understanding marketing or without the LLM understanding the foundry industry, the result can be polished but wrong.* Use AI as a servant, not a decision makerLLMs work best for narrow, practical tasks such as compiling information, sorting notes, drafting first versions, or preparing summaries. It should support human expertise, not replace the expert who understands the process, the customer, and the risk.* Be careful with confidential dataNever put NDA-protected drawings, specifications, or internal notes into public AI systems. The more sensitive the information, the more important it becomes to think about data control, private systems, and who can access the output.* Start with real bottlenecks, not grand visionsInstead of trying to automate an entire foundry at once, start where AI can remove low-value manual work. The practical value comes from reducing friction in specific tasks while keeping a human in control.“We can do amazing things, but who cares if no one sees them?”Watch or listen to GN 70 to hear Fabian and Staffan test what AI gets wrong about casting, why that matters for new business development, and how foundries can start using AI by asking the same questions their future customers are already asking.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.See you in the Podcast,Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

Rheocasting is one of the most discussed, misunderstood, and often misjudged technologies in the die casting industry. Some see it as a miracle process. Others remember failed trials from the past and dismiss it completely. In reality, the truth is far more interesting. Rheocasting is neither golden paint nor science fiction. It is a highly capable extension of high-pressure die-casting that opens the door to new alloys, new applications, and new business, but only if it is understood and applied correctly.In this episode, hosts Fabian Niklas and Staffan Zetterström take on the questions they have been hearing for years from foundries, designers, buyers, and engineers. What exactly is Rheocasting? Why did so many early attempts fail? What is solid fraction? Why does flow behaviour change so dramatically? And what does it actually mean in terms of tool life, machine size, leak tightness, and structural performance?What starts as a technical explanation quickly becomes a broader discussion about process discipline, alloy strategy, production stability, and total cost of ownership. If you have ever seen Rheocasting as a niche process or an unstable curiosity, this conversation will give you a very different picture.Key Topics* What Rheocasting actually is, and what it is notA clear explanation of Rheocasting as an addition to high pressure die casting, not a replacement for it, and why it should be seen as a tool to expand the application range of HPDC.* Why did the previous trial castings fail?Why the process does not fix poor die casting fundamentals, and why metal hygiene, vacuum, tooling, and thermal management must already be under control before Rheocasting can deliver results.* Semi-solid slurry, thixotropy, and the importance of solid fractionAn accessible explanation of how slurry behaves, why it may look solid but flow like a liquid under shear, and why the magic only starts once you reach the right solid fraction.* Why older Rheocasting systems struggledA practical look at why so many historical approaches failed in production, and why temperature-controlled systems are not enough when alloy chemistry and liquidus temperature keep shifting in real foundry life.* Why does enthalpy-controlled slurry making change the game?How the RheoMetal approach creates a much more stable slurry condition, and why that stability is one of the key reasons Rheocasting can work reliably in serial production today.* Why alloy selection becomes much more interestingHow Rheocasting opens a much wider alloy window than conventional HPDC, including lower-silicon alloys, stronger heat-treatable alloys, recycled alloys, and materials designed for thermal conductivity or sustainability.* Leak tightness, structural performance, and new applicationsWhy Rheocasting is attractive for demanding parts such as structural castings and high-pressure leak-tight components, where conventional die casting often reaches its limits.* Why machine size can go down while part capability goes upHow reduced projected area, less gating mass, and lower knocking effects can significantly reduce required locking force and machine size.* Tool life, OEE, and the economics behind the processWhy the business case for Rheocasting is not only about part quality, but also about lower tool wear, better stability, and real savings in total cost of ownership.* What Rheocasting could mean for gigacastingsWhy the discussion is shifting from “can it be done?” to “what does it do for OEE, tool lifetime, and large-scale economics?” especially in very large structural applications.“Rheocasting is not Golden Paint”Rheocasting is not a shortcut around good die-casting practices. It does not reward sloppy fundamentals. But when the basics are in place, it becomes a serious industrial tool that can solve problems conventional HPDC cannot solve so easily.That is what makes this episode so valuable. It does not present Rheocasting as hype. It presents it as what it really is, as a process extension with very real technical and commercial advantages, provided you understand the rules of the game.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.See you in the Podcast,Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

The foundry industry is not just fighting cycle time, cost pressure, and shrinking automotive volumes anymore. It also struggles to build effective teams that can actually lead transformation out of the crisis. In this episode, sponsored by the Euroguss, hosts Fabian Niklas and Staffan Zetterström speak with Tiziana Tronci and Isabel Jeschek about why diversity, fresh perspectives, and courageous leadership may become far more important than the industry has been willing to admit.What starts as a conversation about equality quickly becomes something much more fundamental. This Gold Nugget explores why mixed teams outperform closed circles, and why change management is no longer optional if the industry wants to stay relevant. From family-business succession to software developers in stubborn old organizations, from trust and boldness to data and leadership culture, this episode shows that the future of die casting will not be decided by machines alone.If you still think diversity is a side topic, this conversation will likely challenge that assumption.Key Topics* Why diversity is becoming a real success factor in die castingA discussion about why foundries can no longer rely on homogeneous teams and old routines if they want to manage today’s transformation.* How mixed teams improve decision-makingWhy age, gender, background, and professional perspective all matter when companies are forced to rethink markets, business models, and customer needs.* Why is the biggest barrier still mindsetThe real challenge is not technology or economics, but the cultural mentality inside the foundry industry itself.* What leadership must look like during transformationThe role of the leader is not just to decide, but to listen, moderate, give trust, create space, and allow new ideas to develop.* Why courage matters more than routineA conversation about boldness, responsibility, and why managers must dare to bring in people who do not look, think, or work like the old organization.* What happens when outsiders enter a traditional industryBoth guests reflect on how coming from different sectors can be difficult at first, but ultimately becomes a source of freshness, new thinking, and strategic value.* Why change management has to come from the topTransformation cannot simply be dropped into an old structure. It has to be moderated, supported, and actively led by management.* Why data matters, but not without peopleFacts and market analysis are essential, but only become useful when combined with experience, interpretation, and real dialogue across teams.* What the Euroguss Women in Die Casting initiative revealedThe first conference panel showed strong interest across the industry and made clear that this topic is no longer niche, but increasingly strategic.“I don’t hire smart people and tell them what to do. I hire smart people, and they tell me what to do.”This episode is not really about equality as a checkbox topic. It is about performance.The die casting industry is under pressure from declining utilization, shifting customer demands, emerging technologies, and a market that no longer rewards passive routines. In that environment, companies need new competencies, new perspectives, and leaders who are brave enough to let those perspectives challenge the status quo.If the industry wants a future, it has to do more than buy new machines. It has to build new teams, new leadership habits, and new ways of thinking. Because the real question is no longer whether change is needed. It is whether the people leading the change are ready to let others in.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.See you in the Podcast,Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

The Carbon Border Adjustment Mechanism is no longer a future topic. It has already been impacting global supply chains, pricing structures, and competitive dynamics in the casting industry since January 2026.In this episode, hosts Fabian Niklas and Staffan Zetterström sit down with Marcel Duits, CBAM expert, entrepreneur, and president of the International Association for CBAM, to break down what the mechanism actually means in practice. From emission calculations to supply chain risks, from pricing pressure to strategic opportunities, this Gold Nugget explores one of the most disruptive regulatory changes the industry has faced in decades.What starts as a technical explanation quickly turns into a broader discussion about competitiveness, margins, and how prepared (or unprepared) the industry really is. If you think CBAM is just another reporting exercise, this conversation will change your perspective.Key Topics* What CBAM actually is and why it existsA clear explanation of the Carbon Border Adjustment Mechanism and how it creates a level playing field between EU producers and global imports.* Why CBAM becomes financially real in 2027The shift from reporting emissions to actually paying for them, and why many companies underestimate the financial impact.* The massive cost difference between default and actual dataHow missing verified emission data can multiply costs and quickly destroy already thin margins.* Why most companies are still unpreparedFrom lack of awareness to internal complexity, many organizations are only starting to understand CBAM when it’s already becoming urgent.* The hidden complexity of emission calculationsWhy CBAM is not just a sustainability topic, but also involves customs, finance, procurement, and legal departments.* How CBAM is already reshaping global supply chainsShifts toward new sourcing regions, relocation strategies, and the growing importance of low-carbon production.* Why European producers may gain a competitive advantageHow decarbonized production inside the EU can become a strategic benefit rather than a cost burden.* Why sustainability is no longer optional but financialHow CBAM directly links emissions to cost, turning sustainability into a hard business metric.“What CBAM-Surcharge are you going to charge?”CBAM is often treated as a compliance topic. Something for sustainability teams or reporting departments to handle. But as this conversation makes clear, the real impact is happening elsewhere: in pricing, margins, and negotiations with customers.Companies importing aluminium, steel, or cast components may soon face significant cost increases depending on their emission data and sourcing strategy. The difference between being prepared and unprepared is not theoretical. It is expensive!And what makes this moment critical is timing. Many companies are still acting as if CBAM might change or disappear. But in reality, the first consequences are already becoming visible in customer conversations.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.See you in the Podcast,Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

Dirty scrap might look like waste. But inside that messy pile lies one of the biggest opportunities in the aluminum industry.In this episode, hosts Fabian Niklas and Staffan Zetterström talk with Julio Quintero — materials engineer and host of the Dirty Scrap Podcast — about how recycling actually works in practice. From scrapyards to alloy recipes, from sorting technology to geopolitics, the conversation explores how the industry can turn contaminated scrap into high-quality aluminum and why doing it right is not just sustainable, but extremely profitable.What begins as a discussion about recycling quickly evolves into a deeper look at technology, process knowledge, market dynamics, and the uncomfortable inefficiencies still present across the metal supply chain.If aluminum is the material of the future, then scrap might be its most undervalued resource.Key Topics* How dirty scrap becomes high-quality aluminumA step-by-step look at the recycling chain — from scrap collection and sorting to alloying, melting, and casting.* The missing link between scrapyards and secondary smeltersWhy poor communication across the recycling chain leads to lower recovery rates and lost value.* Why “dirty scrap” still contains massive valueHow contamination, coatings, and moisture reduce metal yield, and how the right pretreatment technologies can dramatically increase recoveries.* Rotary furnaces, stack melters, and the importance of the right processWhy melting technology must match the type of scrap being processed to maximize efficiency.* The surprising economics of scrap vs. primary aluminumWhy scrap prices can sometimes exceed primary aluminum due to demand for low-carbon materials.* Can recycled aluminum match primary quality?A discussion about metallurgy, process control, and why secondary aluminum can achieve nearly identical properties with the right practices.* Why do many foundries still waste aluminium?From molten metal literally overflowing onto the shop floor to inefficient melting practices, small operational improvements can unlock significant profit.* The geopolitical reality of aluminum supplyEnergy prices, tariffs, and global trade tensions are reshaping where primary aluminum can realistically be produced.* Sustainability beyond marketing buzzwordsWhy true sustainability is not just about CO₂ numbers, but about producing more metal from the same resources.“Make more out of the same”Recycling aluminum is often framed as an environmental issue. But as Julio explains, it is equally a technological and economic one. When scrap is poorly sorted or improperly melted, large amounts of metal are lost as oxides, dross, or emissions. With better processes and smarter technologies, those losses can be dramatically reduced, meaning more usable aluminum from the same raw material.In other words, sustainability and profitability are often the same thing!The challenge is not the availability of scrap. The challenge is whether the industry is ready to handle it properly.Because in a world where aluminum demand keeps growing, learning how to turn dirty scrap into golden castings might become one of the most valuable skills in the entire supply 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.See you in the Podcast,Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

Young researcher Paul Becker brings a fresh perspective straight from the shop floor and the next generation of the foundry industry. The discussion with the hosts Fabian Niklas and Staffan Zetterström explores what it really means to enter a mature, conservative industry at a time of technological disruption and demographic change. From Rheocasting innovation to the aging workforce, from recruitment challenges to social media visibility, this Gold Nugget examines the uncomfortable but necessary questions shaping the future of casting.Key Topics* Why the foundry industry still struggles to attract young talentA closer look at perception gaps, outdated narratives, and why casting often isn’t even on the radar of students.* What it feels like to enter a conservative industry as a young professionalFirst-hand impressions of navigating established structures, traditions, and slow-changing mindsets.* The real challenges behind adopting new technologies like rheocastingWhy innovation is not just about technology readiness, but also about cultural readiness.* Why recruitment in casting still happens “by accident”How many careers in foundries start randomly, and why that approach may no longer work.* The generational shift nobody can ignore anymoreWhat happens when experienced experts retire, and fewer young engineers replace them?* What young professionals actually expect from employers todayChanging priorities around flexibility, purpose, and development opportunities.* Why flexibility beats rigid work models in modern foundriesA discussion around work culture, trust, and what younger talent values in daily work environments.* The surprising role of social media in saving the industry’s futureHow visibility, storytelling, and digital presence influence whether young people discover casting at all.“Without young talent, the industry stands still.”The foundry industry is facing a silent turning point. A retiring workforce, slow recruitment pipelines, and rising technological complexity are colliding at the same time. This episode doesn’t romanticize the problem; it confronts it head-on.What makes this conversation powerful is its honesty. It’s not about buzzwords like innovation or transformation. It’s about mindset. Flexibility, visibility, and openness to new ways of working will decide whether the next generation joins the industry or chooses something else.If you care about the future of casting, this episode is less about listening and more about reflecting. Because the real question is not whether young talent exists. It’s whether the industry is ready for them.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.See you in the Podcast,Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

For decades, alloys were treated as fixed inputs. One specification. One melting furnace. One way of doing things. In this Gold Nugget, Fabian Niklas and Staffan Zetterström challenge that thinking and explain why alloys have quietly become one of the most powerful strategic tools in the foundry industry.This conversation is not about chemical limits or phase diagrams. It is about margins, differentiation, supply risk, sustainability pressure, and long-term positioning.Alloys are no longer a back-office engineering decision. They sit right in the middle of business strategy. This episode also marks the start of Goldcasting’s alloy focus for 2026. Not as a trend watch, but as a reality check for anyone who wants to stay relevant in the coming years.Key Topics✅ Why the era of one alloy, one product is endingHow OEM requirements, sustainability targets, and scrap availability are forcing a wider and more flexible alloy landscape.✅ Alloy strategy as a competitive moatWhy do foundries that master alloy flexibility raise entry barriers and reduce price-based competition?✅ Scrap as the real bottleneckWhy access to the right scrap streams may become more valuable than access to primary metal, and why this shifts power in the value chain.✅ Gigacastings and the myth of extreme propertiesA critical look at elongation targets, real crash performance, and why simpler alloys may already be good enough in many applications.✅ Trade politics and regulatory pressureFrom tariffs to CBAM and geopolitical tensions, why alloy sourcing is becoming a political and financial issue, not just a technical one.✅ Special alloys and quiet opportunitiesWhy the most attractive business is often not the biggest volumes, but the applications where knowledge, alloy design, and problem-solving matter.Alloys are not about metallurgy alone; they are about positioningOne theme runs through the entire episode: deliberate alloy selection. Designing processes around them. Understanding scrap flows. And using metallurgy as a lever to defend margins instead of eroding them.The industry is moving away from standard alloys, passive supplier roles, and lowest price logic. In their place come specialization, flexibility, and foundries willing to invest in understanding alloys as a strategic asset.This episode also sets the stage for upcoming interviews with experts across recycling, sustainability, primary aluminum, scrap markets, special alloys, and future applications.If you have questions, technical or uncomfortable, send them in. They will shape the conversations ahead.See you in the Podcast,Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 survivalGet 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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

The world’s first international GIGA-Casting Conference has taken the foundry and automotive industry by storm! In this special episode, your hosts, Fabian Niklas and Staffan Zetterström, sit down with Professor Dr.-Ing. Martin Fehlbier, the mastermind behind the event, to discuss the groundbreaking insights, industry shifts, and future challenges of GIGA-Casting.What’s inside this episode?* The rise of large-scale castings – Why battery trays, rear floors, and structural castings are rapidly becoming the new standard in car manufacturing.* Bigger, bigger, bigger? – Exploring the global approaches in China’s rapid expansion, Japan and North America’s strategic balance, and Europe’s existing machine adaptations.* Challenges ahead: Can foundries keep up? – The high cost of new technologies, location challenges, and the logistical implications of bringing casting closer to car manufacturers.* Industry secrets revealed – The key takeaways from the BMW, Ford, Volkswagen, Honda, and Chinese OEM presentations and what these companies are betting on for the future of automotive manufacturing.* Rheocasting & Thixocasting: The underdog processes? – Why these innovative techniques could be the secret to higher efficiency, lower energy consumption, and improved material properties—and why the industry is still hesitant to adopt them.Get Involved:This episode is packed with exclusive insights from the world's top experts in foundry technology. If you want to stay ahead in the GIGA-Casting revolution, this is the one podcast you cannot afford to miss!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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

In this Goldcasting episode, hosts Fabian Niklas and Staffan Zetterström are joined by Raphael Heilig to explore how collaboration and digitalization can define the future of the European die-casting industry. Sponsored by Euroguss365, the discussion addresses industry challenges, innovation's importance, and collective action's transformative power.Episode Highlights* The State of the Industry and the Need for Change: The episode begins with an honest appraisal of the challenges faced by the European die-casting industry, including economic pressures, declining volumes, and intensified competition.* Joint Presence as a Unifying Strength: By uniting around shared goals, such as sustainability, innovative product development, and streamlined value chains, European die-casters can present a stronger, collective front.* Digitalization as a Key to Competitiveness: Tools like artificial intelligence, big data analysis, and advanced software solutions can help the industry reduce time-to-market, enhance product quality, and create meaningful insights.* Learning from Other Industries and Fostering Innovation: Drawing inspiration from more dynamic sectors, such as social media and telecommunications, the die-casting industry has the opportunity to adopt innovative practices, such as KPI-driven performance analysis and digital marketing strategies.* The Call for Collective Action and Cultural Change: Creating shared resources, such as market data dashboards or benchmarking systems, could streamline decision-making and drive innovation.Get Involved:With bold decisions and a unified vision, the European die-casting industry can overcome challenges and thrive in a competitive landscape. Subscribe to the podcast for more insights into shaping the casting world's future!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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

Have you ever wondered why some messages stick while others fade into oblivion? In Gold Nugget 39, we dive deep into the art and science of storytelling. Understand how it captivates, persuades, and ultimately drives action. Whether you're in sales or marketing or just want to be a more compelling communicator, this episode is packed with insights you don’t want to miss!What’s inside this episode?* Why storytelling is a superpower: Storytelling is not just about entertainment; it’s a powerful tool that helps you package information in a way that engages, influences, and sticks with your audience. We explore why humans are wired to respond to stories and how you can use this to make even the most technical or complex topics compelling.* The K.I.S.S. principle: Keep It Simple, Stupid! Complexity kills engagement, and this principle reminds us to focus on clear, relatable messaging instead of overwhelming people with jargon. Learn how top communicators break down their ideas into simple yet powerful messages that anyone can understand.* Winning attention in 6 seconds: In today’s fast-paced digital world, you have only seconds to make an impression before your audience tunes out. Discover the key techniques to capture interest immediately, keep people engaged, and seamlessly guide them from curiosity to commitment.* From Aristotle to Apple: Great storytelling has remained the same for centuries, from Greek philosophers to modern business legends like Steve Jobs. We break down how these masters of persuasion structured their messages and how you can apply these techniques to your own presentations, pitches, and sales strategies.* The five-step storytelling framework: A simple yet highly effective structure that ensures your message flows naturally and resonates deeply. We walk you through the five essential elements of a great story: the introduction, setting the stage, making your case, countering objections before they arise, and delivering a closing that leaves a lasting impact.* Common mistakes in industry talks: Most business presentations fail because they start with irrelevant company introductions, endless slides, and feature overload. We expose these mistakes and show you how to craft a narrative that puts your audience first, making your message more engaging and persuasive.Learn how rhetoric, psychology, and even brain science play a role in making stories irresistible. Plus, real-world examples from die casting, business pitches, and even Steve Jobs' iPod launch!Want to elevate your storytelling game? Tune in now and get ready to transform how you communicate! And don’t forget to like, subscribe, and share this Gold Nugget episode to stay updated on industry innovations!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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

In this episode of Goldcasting, hosts Fabian Niklas and Staffan Zetterström welcome Eric Müller to discuss the role of marketing in shaping the future of the die-casting industry. Sponsored by Euroguss365, the conversation explores the industry's need for better outreach, attracting young talent, the role of modern communication platforms, and fostering collaboration to secure a sustainable future.Eric Müller: "It’s 12 o’clock now, and we need to react."Key Takeaways from the Episode:1. Marketing the Industry to Attract Young Talent: Eric highlights the industry's struggle to engage the next generation of engineers and workers. The die-casting sector, often perceived as old-fashioned, needs to overcome stereotypes and showcase itself as an innovative and secure career choice. 2. Collaboration to Improve Outreach: The episode emphasizes the importance of a unified approach in promoting the industry. Foundries, toolmakers, machine builders, and other stakeholders must work together to create a compelling narrative. 3. Leveraging Social Media for Visibility: Social media platforms are instrumental in reshaping the industry's image. Sharing engaging content showcasing cutting-edge technology or foundry professionals' day-in-the-life perspectives can spark interest among young people.4. Education and Knowledge Transfer: Education is a cornerstone of marketing the die-casting industry. The need to support universities, technical schools, and apprenticeship programs was discussed as essential for cultivating a pipeline of skilled professionals.5. Unified Lobbying and Advocacy: The three argue that the die-casting industry needs stronger lobbying efforts to ensure favourable policies and regulations. Get Involved:The discussion underscores the urgency of marketing the die-casting industry to ensure its long-term sustainability and relevance. By combining innovative outreach strategies with collaboration and education, the sector can secure its future as a cornerstone of global manufacturing. Don’t forget to like, subscribe, and share this Gold Nugget episode to stay updated on industry innovations!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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

We dive into the innovative world of HERA™ microspray release agent with Darko Tomazic from Chem-Trend in this sponsored episode of the Goldcasting Podcast. Packed with insights and real-world applications, Gold Nugget 37 is a must-listen for anyone in the High-Pressure Die-Casting industry.Episode Highlights* Meet Chem-Trend: Darko Tomazic, a Chem-Trend veteran of 26 years, shares how his hands-on expertise helps solve casting challenges across Europe and beyond.* Introducing HERA™: Learn about Chem-Trend’s High-Efficiency Release Agent (HERA™), a revolutionary technology that eliminates water dilution, reduces cycle times, and minimizes environmental impact.* Complex Casting Solutions: As casting demands grow, consider Gigacastings and CO2 compressor parts, HERA™’s precision micro-spraying offers a sustainable and efficient solution.* Success Stories: From reducing cycle times by up to 30% to cutting waste water by 100%, Darko reveals the tangible benefits of adopting HERA™ in real-world foundries.* The Future of Die Casting: Explore industry trends like energy-efficient processes and the shift towards more complex, value-added cast parts to stay competitive in Europe.Success in casting requires a combination of innovative technology, teamwork, and a proactive approach. HERA™ offers foundries a practical solution to address today’s challenges while building a sustainable future.Get Involved:Interested in transforming your foundry? Contact Darko Tomazic or Chem-Trend to start your efficiency journey. Don’t forget to like, subscribe, and share this Gold Nugget episode to stay updated on industry innovations!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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

In this Gold Nugget of the Goldcasting Podcast, we explore the transformative power of employer branding in the foundry industry, sponsored by Euroguss 365. Joined by Carsten König of Grob, Staffan Zetterström and Fabian Niklas dive deep into strategies to attract, retain, and grow the next generation of talent in a competitive global market. Carsten König: “Whining about finding talent isn’t a solution. Tailor your strategy, act on it, and watch the results.” Key Takeaways from the Episode: * Employer Branding Beyond Salary: Employer branding is more than competitive pay—it’s about creating a workplace that young talent wants to join. From showcasing innovation to supporting work-life balance, it’s essential to communicate why your company is worth choosing.* Learning from Tesla and Beyond: Companies like Tesla succeed by branding themselves as aspirational, even in technical industries. While not every foundry can be Tesla, adopting similar principles can elevate your appeal to younger generations. * The German Apprenticeship Advantage: The apprenticeship model is a proven method for building talent pipelines. Grob has successfully implemented this system in Germany, the U.S., Brazil, and China. This approach lets both the company and the apprentice “test the fit” over several years. * Authentic Employee Stories: Forget glossy, corporate videos. Grob’s approach centres on employee stories—authentic, day-in-the-life perspectives shared by apprentices and employees. These clips, focused on the individual rather than the company, resonate with younger audiences across platforms like Instagram, TikTok, and YouTube. * Regional Strategies for Global Impact: Recruitment efforts must adapt to local cultures, languages, and platforms. What works in Germany might not work in China or Korea. A decentralised approach ensures you reach the right talent on the right channels. Tune In to the Episode: This episode is a must-listen for any foundry looking to stand out in today’s tight talent market. Whether you’re a global player or a smaller company, there’s something here for everyone. Start building your employer brand today—it’s an investment in the future of your workforce and your industry. 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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

In this entertaining and reflective Christmas episode of the Goldcasting Podcast, Staffan Zetterström and Fabian Niklas boldly examine their predictions for 2024 and admit where they missed the mark. With plenty of laughs, honest insights, and surprising outcomes, the duo reviews last year’s forecasts and evaluates how the real world unfolded.Highlights:* 2024 Predictions Review: Staffan and Fabian revisit their bold predictions from last year, which ranged from Chinese OEMs expanding into Europe to sustainability efforts and global foundry trends. Did they see it coming, or were they “Toe-less-Joe” moments?* Where They Were Right (and Wrong): BYD’s European expansion? Check. Sustainability exploding? Not quite. They discuss how the CBAM and F-Gas ban predictions stalled and what that means for the industry.* 2025 Predictions: As always, the future holds twists and turns. Get a sneak peek at Staffan and Fabian’s top predictions for 2025, including digitalization in foundries, global production shifts, and the slow emergence of impactful industry marketing.* Real Talk on the Industry: From trade wars to car production woes, the hosts dig into the brutal realities of the European foundry market and explore strategies for thriving amid challenges.If you enjoy lighthearted banter, sharp industry insights, and a dash of New Year’s reflection, this episode is for you. What’s in store for 2025? Tune in to find out and share your own predictions in the comments. Don’t miss the chance to start the year informed, inspired, and ready to tackle what’s next!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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

In this thought-provoking episode of the Goldcasting Podcast, Staffan Zetterström and Fabian Niklas welcome Marco Carlson, Polestar's Technical Project Leader in Metals and Minerals, for an engaging discussion about the brand's far-reaching sustainability initiatives.Highlights:* Polestar's Sustainability Philosophy: Discover how Polestar integrates sustainability with performance, design, and innovation across its operations. The company's renewable energy-powered manufacturing facilities and advanced recycling strategies are just the beginning.* Polestar 2 and Beyond: Learn how 85% of the Polestar 2 is recyclable, setting a new benchmark in the EV industry. Marco also shares the meticulous work behind reducing each vehicle's CO2 emissions by 500 kilograms.* The Polestar Zero Project: Dive into Polestar’s ambitious goal of creating a fully climate-neutral electric vehicle by 2030. Marco explains the "moonshot" mindset needed to rethink automotive design and manufacturing from the ground up.* Challenges and Innovations: Gain insights into the challenges of balancing cost, performance, and environmental impact in an industry that is often slow to adapt. Polestar’s approach stands out as a model of urgency and bold action.* Inspiration for the Future: Marco shares advice for the next generation of engineers and innovators, emphasizing the importance of considering environmental footprints in every step of research and development.This episode is a must-listen for sustainability enthusiasts, automotive professionals, and anyone curious about the future of green mobility. Subscribe and join us as we explore how Polestar leads the charge toward a more sustainable future.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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

Join Fabian Niklas, Staffan Zetterström, and their guest, Benjamin Jung, for this game-changing episode of the Goldcasting Podcast, sponsored by Euroguss 365. In it, we unpack the exciting opportunities for innovation and collaboration in the European foundry industry. In Gold Nugget 33, we dive into the highlights from the Euroguss Executive Circle, who sponsored this episode and explored the power of adopting a network mindset.Why You Should Listen:Whether you're a foundry professional, a policymaker, or simply curious about the future of manufacturing, this episode showcases how cooperation and innovation can revitalize the sector. Discover how strategic collaboration can transform challenges into opportunities, making the foundry industry a cornerstone of sustainable progress.Key Takeaways:* Rethinking Perceptions: The foundry industry is more than its outdated image of grit and grime. With white floors and cutting-edge technology, today’s foundries are clean, sustainable, and innovative. It’s time to change the narrative and attract fresh talent to our "silent hero" sector.* Collaboration as the Catalyst: From reducing a hundred components to one, as seen with Tesla’s giga casting, to influencing policies on energy costs, collaboration is the future. As guest Benjamin Jung asserts, no single foundry or OEM can drive these changes alone—it takes a unified industry.* The Need for Visibility: With little representation on platforms like YouTube or social media, the foundry industry risks invisibility in a world dominated by digital communication. Strategic marketing, from apprenticeships to lobbying, is essential to showcase our relevance, attract new talent, and make our collective voice heard.* European Unity: The Executive Circle offers a unique platform for competitors to collaborate, strategize, and overcome shared challenges, including energy costs and the lack of young professionals in the field. It’s about building trust to secure the future of European foundries.* Leadership and Innovation: Bold leadership and fresh approaches are needed to maintain Europe’s technological edge. From emphasizing the Total Cost of Ownership over the cheapest bids to fostering innovation speed, the episode calls for a cultural shift within the industry.Tune In Now:Listen to Gold Nugget 33 and join the movement to reimagine the foundry industry's role in Europe and beyond. Don’t miss this inspiring call to action for collaboration, visibility, and innovation.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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

In Goldcasting episode 32, we reveal the keys to effective marketing channel use in the foundry industry. Discover how to leverage diverse platforms to create engaging, impactful marketing that resonates with your audience!Episode Highlights:* The Right Channels for Your Message: Learn why your marketing needs tailored content for each platform. From LinkedIn’s professional reach to TikTok’s younger audience, choosing the right channels ensures your message lands where it matters.* Content That Connects: Not all content works in every channel. Explore the importance of educational, inspirational, and entertaining content—specifically, how educational content resonates most with foundry audiences who value technical insights and industry expertise.* Consistency is Key: Consistent posting builds recognition and trust. We discuss how regular, genuine content can keep your brand top-of-mind, especially in a high-stakes B2B market.* YouTube: The Trust Builder: Foundries benefit immensely from YouTube’s 24/7 availability. This channel provides a lasting presence where potential clients can access content conveniently, transforming cold prospects into engaged leads ready to connect.Pro Tip: Start simple and grow. Launch a basic content plan on the platforms that make sense for your business, adjust based on feedback, and create a steady cadence of posts highlighting your unique strengths.Tune in to learn how to make every channel work harder for your brand and prepare for a standout marketing strategy in the foundry industry! 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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

In this episode, Staffan Zetterström and Fabian Niklas explore iconic marketing stunts that reshaped their industries and how foundries can emulate these bold, imaginative campaigns!Episode Highlights:* Michelin Guide's Road to Success: Discover how Michelin started as a tire company but became synonymous with luxury dining. Michelin understood that promoting driving led to more tire sales. This insight birthed the famous Michelin Guide—a powerful lesson in expanding customer engagement beyond direct products.* Red Bull's Extreme Marketing: Red Bull isn't just an energy drink; it’s an action sports phenomenon. Red Bull cemented its brand through skydives, extreme sports, and a Formula 1 team by embracing adrenaline and going where no other soda brands dared to go.* Guinness World Records: An ingenious idea sparked over a pub debate led to a global sensation—Guinness leveraged curiosity and competition to keep their brand relevant and memorable for decades.* Virgin Airlines' Edge: Richard Branson's Virgin Airlines took risks, from beautiful marketing to onboard bars, turning flights into an unforgettable experience. It wasn’t just flying; it was a brand journey.Key Takeaways for Foundries: The foundry industry can adapt these powerful strategies by:* Embracing bold, unexpected ideas.* Focusing on repeat visibility—your brand has to be seen as trusted.* Using channels creatively, from LinkedIn for professional networking to TikTok for broader engagement.* Showcasing your unique personality and making memorable impressions!Tune in to explore how these iconic campaigns hold the secret to unforgettable marketing that can reshape brand presence and drive growth, even in traditional industries like foundries.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 Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

In this lively episode of the Goldcasting Podcast, Stefan Zetterström and Per Jansson take Fabian Niklas and you as a listener on a journey to the recent NADCA show, where they explored the latest trends in die casting technology and industry outlooks. They share firsthand insights from the North American Die Casting Association (NADCA) event, offering a glimpse into how the U.S. die-casting industry compares to its European counterpart.Highlights:* The NADCA Show Experience: Stefan and Per recap their experience at NADCA, emphasizing its intimate setting. Despite its smaller size, the show attracted key players and offered an excellent platform for networking and learning.* U.S. vs. Europe in Casting: They discuss the subtle yet impactful differences between the U.S. and European HPDC markets. They find the U.S. market more dynamic and willing to embrace new technologies rapidly, while Europe tends to take a more cautious, long-term approach.* Spotlight on Innovation: The hosts detail new technologies showcased at NADCA, such as advancements in Rheocasting. They highlight how American companies are pushing boundaries, often more willing to try unproven methods than their European peers.* Cultural Differences in Business Attitude: Stefan and Per note that U.S. businesses are solution-focused and embrace a culture where failure is seen as a stepping stone, unlike Europe’s risk-averse mindset. This, they suggest, helps drive the quicker adoption of new technologies and innovation in the U.S.Tune in to hear more about the exciting developments in die casting and how the unique cultural differences between the U.S. and Europe shape the industry’s future. This episode provides valuable insights for anyone interested in the global casting landscape, especially those curious about where the industry is headed.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 world of casting. Don’t forget to ask questions, write comments, or make suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

Welcome to Episode 29 of the Goldcasting Podcast! In this episode, we dive into the world of aluminium alloy A380 (also known as 226 in some regions)—a versatile material that forms the backbone of numerous casting applications. Unlike what the title might suggest, we are not discussing the Airbus A380; instead, we focus on how this alloy can drive your projects to new heights, offering profitable opportunities in both the automotive and non-automotive sectors.We start by revisiting the opportunities we highlighted six months ago in Gold Nugget 15 “Nominations to Grab in 2024”. We then discussed which projects to target to maximise growth and profits in the die-casting industry. As we approach the end of 2024, we look back at those recommendations to see how things have unfolded and what new opportunities have emerged. This episode also presents a fresh perspective on leveraging castings made out of A380/226 to their full potential.With its high copper content and good strength, this alloy is used in various applications, from automotive components to non-automotive parts. Many of these projects face issues like high tool wear or porosity. We discuss how switching to Rheocasting can lower production costs, minimise defects, and provide a competitive edge without significantly changing the existing alloy specification. As we navigate these topics, we also explore the broader market dynamics influencing the casting industry. We touch on recent developments in the automotive sector, including OEMs like Volkswagen announcing plant closures and other companies experiencing financial strain. These shifts are creating both challenges and opportunities for foundries, emphasising the need for adaptability and strategic planning. By identifying and targeting niche markets, companies can position themselves to capitalise on the industry's current transformations.This episode is essential listening for anyone looking to stay ahead of the curve in the die-casting industry. You’ll learn about the latest trends, discover new ways to optimise your projects, and gain valuable insights into navigating the ever-changing market landscape. Whether you are a seasoned industry veteran or new to the field, this episode provides the tools and knowledge you need to thrive.Follow and subscribe to the Goldcasting Podcast on your favourite platform so you never miss an episode. Stay informed, stay competitive, and keep your casting projects flying high!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 world of casting. Don’t forget to reach out with your questions, comments, or suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

In episode 28 of the Goldcasting Podcast, we dive deep into the advancements transforming the die casting industry. Fabian Niklas and Staffan Zetterström sit down with Russ Dieffenbach and Andy Mulroy from Hypertherm Inc., who sponsored this Gold Nugget, to discuss the impact of plasma technology on HPDC, from small multi-cavity castings to large gigacastings.Key Highlights:* The Evolution of Die Casting Machines: Discover how Gigacasting has pushed the boundaries of size and efficiency in die casting. Russ and Andy explore how the industry is adapting to the growing demand for larger, more complex parts.* Plasma Technology's Role in Automotive Manufacturing: Learn about Hypertherm's cutting-edge plasma, water jet, and fiber laser solutions. They explain how plasma technology is revolutionising the industry by offering flexibility, cost-efficiency, and scalability—key to high-pressure die casting in the automotive sector.* Uptime and Efficiency Gains: We dive into how Hypertherm’s plasma solutions are addressing long-standing issues with mechanical trim presses, improving uptime, reducing maintenance needs, and ultimately optimising production workflows.* Sustainability and Cost-Reduction: Russ and Andy shed light on how plasma can contribute to more efficient material usage, reducing the environmental impact and manufacturing costs.Whether you’re in the die casting or automotive industry, this episode provides valuable insights into how emerging technologies like plasma can significantly improve operational efficiency and product quality. Tune in to learn how Hypertherm is driving the future of die casting!If you’re at the NADCA exhibition, visit their booth and see the plasma cutters for yourself. You will be shocked at how inexpensive their solutions are! Visit hypertherm.com for more information, or contact Andy via email ([email protected]), when you want to get more information.Also, don’t forget to subscribe to the Goldcasting Podcast to not miss insights into the HPDC world every two weeks: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 world of casting. Don’t forget to reach out with your questions, comments, or suggestions for future episodes. Until next time, keep casting strong!Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

Welcome to Gold Nugget 27. In this episode of the Goldcasting Podcast, Staffan Zetterström and Fabian Niklas dive deep into the world of Gigacasting. We question Joakim Rosenqvist, a global sales manager at ABB Robotics, about how automation and robotics transform the manufacturing process for large aluminium castings.Joakim shares insights on the advantages and challenges of GigaCasting, including how it is reshaping the industry by reducing the number of parts needed in car production, enhancing sustainability, and optimising cost. We explore the benefits of using robots for various tasks like milling, drilling, and deburring and how this reduces reliance on traditional CNC machines. Joakim discusses the impact of automation on capital expenditure (CapEx) and the innovative ways robots are being deployed in foundries around the world, from China to North America.We also touch upon the environmental implications of GigaCasting, such as the reduced carbon footprint and increased use of recyclable materials. Joakim highlights the learning curve in adopting this technology, from mastering new casting techniques to overcoming quality control challenges. Additionally, we discuss the potential of artificial intelligence and machine learning to revolutionise manufacturing processes and address current limitations.If you’re passionate about the future of the foundry industry, interested in the role of robotics in automotive manufacturing, or curious about how Gigacasting is set to change the landscape of car production, this episode is a must-listen!Tune in to learn:* The benefits and challenges of GigaCasting in modern car production.* How robots are enhancing the efficiency of manufacturing processes.* The global trends in Gigacasting include the rapid adoption in China and the slower uptake in Europe and North America.* The potential of AI and machine learning to further innovate the industry.* Insights into the future of automation, robotics, and foundry processes.Don’t miss out on this insightful conversation! Remember to subscribe for more episodes and stay ahead in the ever-evolving world of the aluminium foundry business.We'll see you in the comment section, or you can hear us again in our next Gold Nugget on September 19!Enjoy the Gold Nugget,Staffan and Fabian Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

In this special episode of the Goldcasting Podcast, join hosts Fabian Niklas and Staffan Zetterström as they guide you through a selection of must-listen episodes to enjoy during the summer break. Whether you're on the beach or embarking on a road trip, now is the perfect time to dive into our treasure trove of content.We begin by thanking our dedicated listeners for their support and engagement. With over 36,000 listens and 80,000 impressions each month, your enthusiasm fuels our journey.As we take a break, we recommend starting with some of our favourite episodes:* Gold Nugget 13: Do you have the right Captains?* Gold Nugget 11: Tesla - The old Newcomer with Pranay Verma* Gold Nugget 14: Inside a Purchasers Head with Gunnar Wallin* Gold Nugget 9: Dr. Per Jansson changes the World one Slurry at the time* Gold Nugget 15: Top 10 Nominations to grab in 2024* Gold Nugget 6: Marketing Disaster* Gold Nugget 5: High Mix - Low Volume* Gold Nugget 20: The Aluminium Industry with LingeFabian and Stefan also shared their personal highlights and explained why these episodes stood out. From discussions with Italpress and Bühler managers to Tesla insights, our podcast features a diverse range of industry leaders and topics.Each episode is packed with valuable information you can apply immediately to enhance your operations and product portfolio. Use this summer to catch up and prepare for new ideas to implement post-vacation.Share your experiences in the comments on LinkedIn or Substack. Are you more of the email type, or do you have an exciting topic for us? Send an email to [email protected] podcast is about how to make money in the foundry industry. Is there any money, or is it just squeezing everyone to save cents? So, we're not talking about properties, microstructures, atoms, or casting parameters. We want to speak to everyone in the industry.We'll see you in the comment section, or you can hear us again in our next Gold Nugget on September 5th!Have a great summer,Staffan and Fabian Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

In this milestone 25th episode of the Goldcasting Podcast, we are thrilled to welcome Dr. Markus Hofer, a luminary in the field of die-casting from Bühler AG. Join us as we deep dive into the die-casting industry's latest disruption - The Megacasting.Markus Hofer, the business development wizard behind Bühler's success, enlightens us on the strategy in gigacasting. Discover how Bühler navigated the challenging transition of the automotive industry from internal combustion engines to electric vehicles, propelling their die-casting machine business to new heights.In this Gold Nugget, we discuss:* The pivotal decisions that led to the development of the 8,400 and 9,200-ton machines.* The intricate interplay between system components, processes, and alloys in megacasting.* Insights into the future of die casting and strategic advice for young professionals entering the industry.* The competitive dynamics of aluminium die castings and what we can learn from other industries. Markus highlights the importance of innovation and adaptability.Whether you are an industry professional, a casting enthusiast, or someone curious about the future of manufacturing, this episode is packed with valuable insights and forward-thinking perspectives.Tune in to explore how Bühler is turning aluminium into gold and setting new benchmarks in the die-casting industry. Don't forget to subscribe and stay updated with our latest episodes!Share your experiences in the comments on LinkedIn or Substack. Are you more of the email type, or do you have an exciting topic for us? Send an email to [email protected] podcast is about how to make money in the foundry industry. Is there any money, or is it just squeezing everyone to save cents? So, we're not talking about properties, microstructures, atoms, or casting parameters. We want to speak to everyone in the industry.We'll see you in the comment section, or you can hear us again in our next Gold Nugget on the first of August!Best regards,Staffan and Fabian Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

Welcome to our 24th Gold Nugget, where we interview Peter Sell from ItalPresseGauss about the Giant Castings. IPG just released their toggle-free 11.000-ton press, so the question is: Where is the economic limit of Gigacasting?Peter describes it best when he says: “Don’t think of your castings as parts! Think of them as money. And how many 100-dollar bills do you want to make wrong?” Based on that quote, we explore what you need to run a profitable foundry, independent of machine size. We also discuss the additional complexity of scaling a matchbox toy into a real car.Listen to Gold Nugget and learn about the merger of disciplines in casting:Share your experiences in the comments on LinkedIn or Substack. Are you more of the email type, or do you have an exciting topic for us? Send an email to [email protected] podcast is about how to make money in the foundry industry. Is there any money, or is it just squeezing everyone to save cents? So, we're not talking about properties, microstructures, atoms, or casting parameters. We want to speak to everyone in the industry.We'll see you in the comment section, or you can hear us again in our next Gold Nugget on Gigacastings on July 4th!Best regards,Staffan and Fabian Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

Welcome to our 23rd Gold Nugget. The US announced a 100% tax on Chinese EVs, and the EU is launching CBAM in 2026. In this episode, we examine the consequences of such protective measures for our industry.We compare the current situation with past events and predict the possible outcomes for European foundries. We also discuss the competitive advantages of certain electric vehicle brands. And spoiler alert: it is not the obvious answer.Listen to Gold Nugget and learn how to position your foundry:Share your experiences in the comments on LinkedIn or Substack. Are you more of the email type, or do you have an exciting topic for us? Send an email to [email protected] podcast is about how to make money in the foundry industry. Is there any money, or is it just squeezing everyone to save cents? So, we're not talking about properties, microstructures, atoms, or casting parameters. We want to speak to everyone in the industry.We'll see you in the comment section, or you can hear us again in our next Gold Nugget on Gigacastings on July 4th!Best regards,Staffan and Fabian Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

Welcome to our 22nd Gold Nugget with Dr. Armin Wiedenegger from voestalpine Additive Manufacturing. In this episode, you will get a Masterclass on the Thermal Management of normal and Gigacasting tools. We reverse-engineer what makes a better and cheaper casting. Be aware that it requires you to change your perception, as the only constant in the world is changing, not your tooling concept. We will tell you what you need to know about foundry technology and tool design to enable cost savings and get your foundry back on high profitability.Listen to Gold Nugget and learn how to improve the lifetime of your tools:Share your experiences in the comments on LinkedIn or Substack. Are you more of the email type, or do you have an exciting topic for us? Send an email to [email protected] podcast is about how to make money in the foundry industry. Is there any money, or is it just squeezing everyone to save cents? So, we're not talking about properties, microstructures, atoms, or casting parameters. We want to speak to everyone in the industry.We'll see you in the comment section, or you can hear us again in our next Gold Nugget on June 20th!Best regards,Staffan and Fabian Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

Welcome to our 21st Gold Nugget with Erik Petré from Stena Aluminium. In this episode, we discuss the sustainability of aluminium alloys. You might be surprised, but the major contributor to the carbon footprint of secondary alloys is not the recycling process; it is the silicon you must add.As the title suggests, Stena Aluminium is the King of Scrap, so they know how to achieve low carbon emissions for high-quality casting alloys. Erik shares that in the podcast with us and focuses on the challenges of secondary Gigacasting alloys.Listen to Gold Nugget and learn about the challenges of secondary aluminium alloys:Share your experiences in the comments on LinkedIn or Substack. Are you more of the email type, or do you have an exciting topic for us? Send an email to [email protected] podcast is about how to make money in the foundry industry. Is there any money, or is it just squeezing everyone to save cents? So, we're not talking about properties, microstructures, atoms, or casting parameters. We want to speak to everyone in the industry.We'll see you in the comment section, or you can hear us again in our next interview on June 6th!Best regards,Staffan and Fabian Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe