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Buhler adds Volvo Cars to its megacasting customers

The Swedish premium car brand Volvo Cars has purchased two Carat 840 diecasting cells for its factory in Torslanda, Sweden. The Carat 840, along with Carat 920, Bühler’s largest diecasting solutions, were launched in 2021. Buhler reports that these solutions have become “very attractive” for customers in the automotive industry.

In October 2021, Bühler launched the Carat 840 and the Carat 920 with locking forces of up to 92,000 kilonewtons (kN). With these solutions, customers can produce structural castings for the automotive body in white assemblies, known as megacastings. This expansion builds on the success of the Carat 560 and 610, which have up to 6,000t locking force and have been on the market since 2020.


Nearly a century of experience in diecasting 

Bühler has been active in diecasting for over 90 years and supported customers with thousands of applications. Megacasting is a further development of the structural process (complex, thin-walled parts produced using diecasting) which Bühler has driven since the early 2000s. Bühler’s Carat series is a successful solution bringing megacasting production to the next level. 

Cornel Mendler, managing director of Bühler Die Casting, says: “Megacasting is of utmost importance for the entire diecasting industry. Megacasting gives the trend towards structural casting another push by extending the range of applications to complete body sections with the use of the new large Carat solutions with up to 92,000kN locking force.” 

With the introduction of the Carat 840 and 920 and its vast diecasting experience, Bühler has further developed its solutions to be able to provide complete cell solutions for ever larger projects. Two Carat 840 diecasting cells will be delivered to Volvo Cars for its factory in Torslanda.


Customer focused innovations  

“Volvo Cars is among the first carmakers to adopt the megacasting process. The fact that Volvo Cars has chosen Bühler for two complete Carat 840 cells shows that we have the right products and services for this intensively discussed innovation in the automotive industry,” says Mendler. 

“Especially for such large projects, thinking about the entire diecasting cells from the melting furnace to the handling of the final part is essential. Bühler has the competence to deliver these complete diecasting solutions.”


Groundbreaking megacasting 

Megacasting is considered groundbreaking by many car manufacturers who are moving in this direction or thinking about adopting this trend. Megacastings reduce complexity in production by enabling between 70 to 100 parts to be replaced by a single die cast part. These single-piece castings will generally be produced close to the automotive assembly line, which allows for better integration and reduced transport.

Aluminium castings have the potential to be almost CO2 neutral, when using low CO2 aluminium alloys and biogas for the melting furnaces. The aluminium that goes into overflows can be remelted directly and reused in the diecasting cell, thereby avoiding transport and recycling. Thinking a step further, the usage of lighter aluminium parts can reduce the energy consumption of the cars over their entire lifecycle. 

Bühler offers the right expertise when it comes to megacasting. “Bühler is the number one solution provider for diecasting, offering complete diecasting cells with a full range of services in all relevant regions. As of today, half of all structural castings for the automotive body in white production are produced on Bühler machines. With more than 800 machines in operation, the Bühler Carat series is the most popular diecasting solution to produce structural parts,” says Mendler.