Industry news
Next-Generation Cast Components Enabled by Physics–AI Driven Technologies
Amidst the accelerating transformation of the new energy vehicle and high-end equipment manufacturing industries, die-cast components are undergoing a profound technological evolution characterized by lightweight construction, micron-level precision, and geometrically complex designs. This shift is propelled by the dual imperatives of energy efficiency and structural performance, driving demand for components that offer superior strength-to-weight ratios, enhanced thermal management, and integrated functional features. Yet, traditional die-casting methodologies—deeply rooted in operator experience and empirically refined over decades—increasingly exhibit critical vulnerabilities in reproducibility, scalability, and adaptive control. The inherent variability of manual intervention, coupled with the growing sophistication of alloy systems and structural requirements, has rendered conventional approaches inadequate in addressing the multifaceted challenges of defect mitigation, throughput optimization, and sustainable cost management.
In this context, an integrated intelligence paradigm known as physics-AI converged manufacturing has emerged as a transformative enabler. This approach strategically unites physics-based computational modeling—which encapsulates fundamental principles of solidification dynamics, thermal-mechanical stress, and microstructure evolution—with data-driven artificial intelligence capable of real-time learning, pattern recognition, and predictive optimization. By establishing a closed-loop feedback system between simulated process parameters and actual production data, this synergy enables not only proactive defect identification and root-cause analysis but also autonomous adjustment of casting conditions such as injection velocity, temperature gradient, and cooling rate.
The implications of this technological convergence extend far beyond incremental improvement. It facilitates the design and manufacturing of previously unattainable component architectures—such as thin-walled, high-integrity structural parts with embedded cooling channels or multi-material hybrid assemblies—while significantly reducing development lead time, material consumption, and energy footprint. Furthermore, by digitizing and encoding domain expertise into scalable AI models, the technology democratizes advanced manufacturing capability, allowing both established enterprises and innovative entrants to achieve higher levels of operational excellence and product innovation.
Thus, physics-AI intelligent-driven technology represents not merely an incremental upgrade, but a foundational shift toward a more adaptive, precise, and sustainable die-casting industry. It stands as a pivotal breakthrough in empowering the next generation of mobility, aerospace, and advanced industrial systems, positioning the die-casting sector at the forefront of the smart manufacturing revolution.
The 21st China Die Casting Congress is honored to invite Sajjad Amirkhanlou, Founder & CEO of the UK-based company MetalNx, to present on-site about a new generation of die-cast components driven by the synergy of physics-based models and AI. The presentation will focus on the core pathways through which physics-AI technology empowers the next generation of die-cast components, explaining how to integrate industry expertise, physical knowledge of alloys and processes, and AI algorithms to drive innovation in aluminum and magnesium alloy casting manufacturing. The goal is to achieve enhanced product performance and greater manufacturing efficiency.
Brief Vita of the Speaker
Sajjad Amirkhanlou
Founder & CEO
Sajjad is the founder and CEO of MetalNx, bringing more than two decades of experience in physics- and AI-driven metal-product development, industrialisation, and advanced metal manufacturing. With a background that includes postdoctoral research at the University of Oxford and senior executive roles within corporate organisations, he has played a pivotal role in scaling businesses and commercialising cutting-edge innovations.
His track record spans the industrialisation of numerous metal products across aerospace, motorsport, automotive, electronics, and advanced manufacturing. The author of more than 60 papers and patents, he has led major development and industrialisation programmes, consistently delivering sustainable, high-impact technological advancements.
Brief Abstract of the Presentation
In this work, we present how the next generation of aluminium and magnesium cast components is expected to be manufactured by drawing on the industry’s long–established domain expertise, a deep physical understanding of alloys, processing steps, manufacturing parameters, and heat treatments, together with modern physics–AI predictive algorithms. This integrated approach enables the development of superior and sustainable casting components and more efficient manufacturing processes.
Company Introduction
MetalNx is a deep-tech start-up specialising in the design and industrialisation of metal castings and products through the use of physics-based and artificial intelligence (AI)/machine learning (ML) driven digital tools. MetalNx brings together a highly qualified team with strong academic credentials, including former University of Oxford researchers, complemented by more than 50 years of combined industrial experience.
About Die Casting Congress
The 21st China Die Casting Congress will be held in Wuhan, China from March 25 to 27, 2026. Under the theme of "Al & Mg, Casting a Lighter Future", it will gather global industry leaders to jointly shape the lightweight future.
Also organized by the Foundry Institution of Chinese Mechanical Engineering Society (FICMES), CHINA DIECASTING & CHINA NONFERROUS expo 2026, will be held from July 15 to 17, 2026 at Shanghai New International Expo Centre (Halls N1–N4). As Asia's largest specialized exhibition for die casting and nonferrous foundry, this edition, under the theme "Twin Engines: Al & Mg, A Lightweight Future," is expected to span 49,200 square meters, attract over 600 exhibitors, and welcome 28,000 professional visitors. Colleagues from around the world are warmly invited to visit and exchange insights.
Register to be a delegate! Now!
In this context, an integrated intelligence paradigm known as physics-AI converged manufacturing has emerged as a transformative enabler. This approach strategically unites physics-based computational modeling—which encapsulates fundamental principles of solidification dynamics, thermal-mechanical stress, and microstructure evolution—with data-driven artificial intelligence capable of real-time learning, pattern recognition, and predictive optimization. By establishing a closed-loop feedback system between simulated process parameters and actual production data, this synergy enables not only proactive defect identification and root-cause analysis but also autonomous adjustment of casting conditions such as injection velocity, temperature gradient, and cooling rate.
The implications of this technological convergence extend far beyond incremental improvement. It facilitates the design and manufacturing of previously unattainable component architectures—such as thin-walled, high-integrity structural parts with embedded cooling channels or multi-material hybrid assemblies—while significantly reducing development lead time, material consumption, and energy footprint. Furthermore, by digitizing and encoding domain expertise into scalable AI models, the technology democratizes advanced manufacturing capability, allowing both established enterprises and innovative entrants to achieve higher levels of operational excellence and product innovation.
Thus, physics-AI intelligent-driven technology represents not merely an incremental upgrade, but a foundational shift toward a more adaptive, precise, and sustainable die-casting industry. It stands as a pivotal breakthrough in empowering the next generation of mobility, aerospace, and advanced industrial systems, positioning the die-casting sector at the forefront of the smart manufacturing revolution.
The 21st China Die Casting Congress is honored to invite Sajjad Amirkhanlou, Founder & CEO of the UK-based company MetalNx, to present on-site about a new generation of die-cast components driven by the synergy of physics-based models and AI. The presentation will focus on the core pathways through which physics-AI technology empowers the next generation of die-cast components, explaining how to integrate industry expertise, physical knowledge of alloys and processes, and AI algorithms to drive innovation in aluminum and magnesium alloy casting manufacturing. The goal is to achieve enhanced product performance and greater manufacturing efficiency.
Brief Vita of the Speaker
Sajjad Amirkhanlou
Founder & CEO
Sajjad is the founder and CEO of MetalNx, bringing more than two decades of experience in physics- and AI-driven metal-product development, industrialisation, and advanced metal manufacturing. With a background that includes postdoctoral research at the University of Oxford and senior executive roles within corporate organisations, he has played a pivotal role in scaling businesses and commercialising cutting-edge innovations.
His track record spans the industrialisation of numerous metal products across aerospace, motorsport, automotive, electronics, and advanced manufacturing. The author of more than 60 papers and patents, he has led major development and industrialisation programmes, consistently delivering sustainable, high-impact technological advancements.
Brief Abstract of the Presentation
In this work, we present how the next generation of aluminium and magnesium cast components is expected to be manufactured by drawing on the industry’s long–established domain expertise, a deep physical understanding of alloys, processing steps, manufacturing parameters, and heat treatments, together with modern physics–AI predictive algorithms. This integrated approach enables the development of superior and sustainable casting components and more efficient manufacturing processes.
Company Introduction
MetalNx is a deep-tech start-up specialising in the design and industrialisation of metal castings and products through the use of physics-based and artificial intelligence (AI)/machine learning (ML) driven digital tools. MetalNx brings together a highly qualified team with strong academic credentials, including former University of Oxford researchers, complemented by more than 50 years of combined industrial experience.
About Die Casting Congress
The 21st China Die Casting Congress will be held in Wuhan, China from March 25 to 27, 2026. Under the theme of "Al & Mg, Casting a Lighter Future", it will gather global industry leaders to jointly shape the lightweight future.
Also organized by the Foundry Institution of Chinese Mechanical Engineering Society (FICMES), CHINA DIECASTING & CHINA NONFERROUS expo 2026, will be held from July 15 to 17, 2026 at Shanghai New International Expo Centre (Halls N1–N4). As Asia's largest specialized exhibition for die casting and nonferrous foundry, this edition, under the theme "Twin Engines: Al & Mg, A Lightweight Future," is expected to span 49,200 square meters, attract over 600 exhibitors, and welcome 28,000 professional visitors. Colleagues from around the world are warmly invited to visit and exchange insights.
Register to be a delegate! Now!
Foundry Institution of Chinese Mechanical Engineering Society
Ms. You Yi
+86 24 25855793
youyi@foundrynations.com
Ms. You Yi
+86 24 25855793
youyi@foundrynations.com
