Efficient use of resources in casting technology

Why EFFECT?

The automotive industry is undergoing a rapid shift towards large, functionally integrated aluminium components, enabled by megacasting and high‑pressure die casting. This transformation brings major efficiency gains – but also new challenges.

Today:

• Large-scale high-pressure die casting (HPDC) risks increased use of virgin aluminium
• Process stability, tool life, and quality control are major bottlenecks
• Recycling of aluminium often leads to downcycling, limiting climate benefits
• Digitalisation and interoperability across the value chain are still fragmented

To unlock the full climate potential of megacasting, a system-level approach is required.

The EFFECT series

EFFECT is a long‑term, mission‑driven research initiative structured as a series of interconnected phases, each building on the results of the previous one going from knowledge building to industrial impact. This approach is designed to enable a system‑level transformation of aluminium die casting towards circular, resilient and net‑zero manufacturing.

The initial phase ran during 2025 and it established feasibility and identified key challenges. The current phase (2026-2027) focuses on developing methods, digital infrastructure and collaboration models while preparing a system demonstrator. A subsequent phase will implement and validate this demonstrator in real industrial environments

The long-term vision is to:

• Enable circular aluminium value chains in Sweden
• Reduce CO₂ emissions by up to 60% for selected components
• Strengthen industrial resilience and resource security
• Establish the foundation for a testbed for sustainable casting

A system perspective – beyond technical development

Unlike many conventional R&D initiatives, EFFECT addresses the entire system, from material and design to process, data, business models and regulation.

Key focus areas include:

• High share of recycled aluminium without compromising performance
• AI-supported conceptual design and faster design loops
• Digital data infrastructure enabling interoperability and traceability
• Process optimisation and in-line quality control
• Tool durability and cost-effectiveness for large castings

This approach integrates technology, digitalisation and collaboration across the value chain and is carried out in close collaboration between industry, academia, and research institutes.

EFFECT focus areas

Sustainable design & materials: Development of circular design principles and A.I.‑supported methods for integrated HPDC components.

Sustainable process technology: Optimisation of HPDC processes for recycled aluminium, including tool lifetime, material flows, and energy efficiency.

Digitalisation and industrial A.I.: Development of digital infrastructure, digital twins, and A.I. models for design, process control, and inspection.

System demonstrator & collaboration: Validation in an industrial environment through demonstration of a fully integrated, digitally enabled, and sustainable HPDC value chain.

EFFECT is financed by the Net Zero Industry research and innovation programme and contributes directly to Climate-neutral manufacturing and Circular use of critical materials. Additionally, the project actively promotes inclusive collaboration and long-term competence building in Swedish industry.