Casting

Casting different metals plays a significant role in Swedish manufacturing. Each year, a hundred Swedish foundries produce 300,000 tonnes of components for heavy vehicles, as well as for the telecommunications, medical technology, wind power, water pumping and furniture industries. Casting is a cost-effective method for the serial production of complex components, as it can often replace the joining of many parts with a single casting. However, success with advanced casting techniques such as Megacasting requires the verification of materials and processes, as well as the correct casting temperature and optimised mould designs to avoid defects. The transition to a circular economy involving increased use of scrap and recycled aluminium requires rigorous process control to ensure productivity and quality, while foundries are streamlining their energy use and phasing out fossil fuels.

RISE contributes to a sustainable, resource-efficient, and circular foundry industry by developing and verifying sustainable casting processes from concept to production. We support the design process for new smart components made from iron, steel and aluminium, helping with everything from selecting and optimising materials to casting simulation and testing in 3D-printed sand moulds, and ultimately producing the finished machined component. We verify microstructure and material properties, and further develop the casting process to avoid defects and ensure quality.