Industry news
World's First Low-Pressure Aluminum Alloy Integrated Front Cabin Makes Its Groundbreaking Debut
Aluminum Alloy Integrated Front Cabin Leads a New Era of Manufacturing Transformation
On January 21, 2026, Jiangsu CASFU Light-Alloy Co., Ltd. successfully launched the world's first low-pressure die-cast aluminum alloy integrated front cabin, marking a significant breakthrough in automotive manufacturing technology. This product was designed as an integrated replacement for a pre-launch steel front cabin of a specific vehicle. By utilizing the low-pressure die-casting process and a tubular hollow structure, the weight was reduced from 71kg to 45kg, achieving a weight reduction of 36.7%. This innovation applies the low-pressure casting process to large-scale structural components for the first time, abandoning the complex assembly processes of traditional steel stamping and welding. The integrated molding significantly simplifies the process and greatly enhances product strength and stability. Its unique tubular hollow structure, inspired by biomechanical design, perfectly balances lightweighting with high rigidity and provides excellent crumple and energy absorption performance during collisions. Furthermore, the product demonstrates exceptional filling performance, with a maximum filling height of 1 meter and a minimum wall thickness of just 3.8mm. The project was completed by CASFU in collaboration with General Motors China Science Lab and Superband Mould, pooling the advantageous resources of all parties. This achievement not only sets a new benchmark for automotive parts manufacturing but also opens up a new path for lightweighting and process innovation in the automotive industry.
Preview Debut: The 21st China Die Casting Congress
As the annual grand event of the die-casting industry, this revolutionary integrated front cabin will be publicly unveiled for the first time at the 21st China Die Casting Congress.
Front Cabin
At that time, Mr. Sun Jingying, CEO of Jiangsu CASFU Light-Alloy Co., Ltd., will be present at the scene and deliver a keynote report titled "Development of LPDC Process for Integrated Aluminum Alloy Front Cabin Frame." He will delve into the logic behind the hollow structure design that achieves a 35% lightweighting effect, and explain how low-pressure casting provides a "low-cost, high-performance" new concept for large-scale new energy vehicle body parts.
Brief Vita of the Speaker
Sun Jingying
CEO
Jiangsu CASFU Light-Alloy Co., Ltd.
He holds a Ph.D. from a joint training program between Northeastern University and BMW Brilliance. He serves as the CEO of CASFU, expert member of China Foundry Society Die Casting Council, and technical expert of the Foundry Institution of Chinese Mechanical Engineering Society. His main research domains include lightweight design, low-pressure die casting, high-pressure die casting, semi-solid casting, and casting computer simulation. With over ten years of experience in casting simulation and seven years of work experience at BMW, he is proficient in the process design and optimization of low-pressure casting for key components such as aluminum alloy subframes, engine blocks, and battery trays.
Brief Abstract of the Presentation
Low Pressure Die Casting (LPDC) has achieved remarkable results in the production of thin-walled hollow aluminum alloy subframes. The successful application of LPDC to large thin-walled components has also provided a new casting concept for GIGA castings. CASFU has jointly developed an integrated LPDC front cabin with an OEM. The design adopts a hollow structure, which achieves a weight reduction of 35%. Computer simulation was applied to optimize the layout of the gating system, and finally mass production of the casting was realized. After T6 heat treatment, the casting exhibits high mechanical properties. The investment cost of LPDC production lines and molds is much lower than that of HPDC, providing a new low-cost process solution for OEMs to develop large-scale integrated castings.
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.
Register to be a delegate! Now!
Foundry Institution of Chinese Mechanical Engineering Society
Ms. You Yi
+86 24 25855793
youyi@foundrynations.com
CHINA DIECASTING & CHINA NONFERROUS 2026
CASFU will exhibit at Asia's largest specialized die-casting and non-ferrous exhibition—CHINA DIECASTING & CHINA NONFERROUS 2026 (Shanghai New International Expo Center, Halls N1-N4) from July 15-17, 2026, at Booth N4B33 (Magnesium Alloy Casting Zone). Under the theme "Twin Engines: Al & Mg, A Lightweight Future", this edition is expected to span 49,200 square meters, feature 600+ exhibitors, and attract 28,000 professional visitors. Enterprises and professionals from the global die-casting and non-ferrous casting industry chain are welcome to visit for exchange and cooperation.
On January 21, 2026, Jiangsu CASFU Light-Alloy Co., Ltd. successfully launched the world's first low-pressure die-cast aluminum alloy integrated front cabin, marking a significant breakthrough in automotive manufacturing technology. This product was designed as an integrated replacement for a pre-launch steel front cabin of a specific vehicle. By utilizing the low-pressure die-casting process and a tubular hollow structure, the weight was reduced from 71kg to 45kg, achieving a weight reduction of 36.7%. This innovation applies the low-pressure casting process to large-scale structural components for the first time, abandoning the complex assembly processes of traditional steel stamping and welding. The integrated molding significantly simplifies the process and greatly enhances product strength and stability. Its unique tubular hollow structure, inspired by biomechanical design, perfectly balances lightweighting with high rigidity and provides excellent crumple and energy absorption performance during collisions. Furthermore, the product demonstrates exceptional filling performance, with a maximum filling height of 1 meter and a minimum wall thickness of just 3.8mm. The project was completed by CASFU in collaboration with General Motors China Science Lab and Superband Mould, pooling the advantageous resources of all parties. This achievement not only sets a new benchmark for automotive parts manufacturing but also opens up a new path for lightweighting and process innovation in the automotive industry.
Preview Debut: The 21st China Die Casting Congress
As the annual grand event of the die-casting industry, this revolutionary integrated front cabin will be publicly unveiled for the first time at the 21st China Die Casting Congress.
Front Cabin
At that time, Mr. Sun Jingying, CEO of Jiangsu CASFU Light-Alloy Co., Ltd., will be present at the scene and deliver a keynote report titled "Development of LPDC Process for Integrated Aluminum Alloy Front Cabin Frame." He will delve into the logic behind the hollow structure design that achieves a 35% lightweighting effect, and explain how low-pressure casting provides a "low-cost, high-performance" new concept for large-scale new energy vehicle body parts.
Brief Vita of the Speaker
Sun Jingying
CEO
Jiangsu CASFU Light-Alloy Co., Ltd.
He holds a Ph.D. from a joint training program between Northeastern University and BMW Brilliance. He serves as the CEO of CASFU, expert member of China Foundry Society Die Casting Council, and technical expert of the Foundry Institution of Chinese Mechanical Engineering Society. His main research domains include lightweight design, low-pressure die casting, high-pressure die casting, semi-solid casting, and casting computer simulation. With over ten years of experience in casting simulation and seven years of work experience at BMW, he is proficient in the process design and optimization of low-pressure casting for key components such as aluminum alloy subframes, engine blocks, and battery trays.
Brief Abstract of the Presentation
Low Pressure Die Casting (LPDC) has achieved remarkable results in the production of thin-walled hollow aluminum alloy subframes. The successful application of LPDC to large thin-walled components has also provided a new casting concept for GIGA castings. CASFU has jointly developed an integrated LPDC front cabin with an OEM. The design adopts a hollow structure, which achieves a weight reduction of 35%. Computer simulation was applied to optimize the layout of the gating system, and finally mass production of the casting was realized. After T6 heat treatment, the casting exhibits high mechanical properties. The investment cost of LPDC production lines and molds is much lower than that of HPDC, providing a new low-cost process solution for OEMs to develop large-scale integrated castings.
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.
Register to be a delegate! Now!
Foundry Institution of Chinese Mechanical Engineering Society
Ms. You Yi
+86 24 25855793
youyi@foundrynations.com
CHINA DIECASTING & CHINA NONFERROUS 2026
CASFU will exhibit at Asia's largest specialized die-casting and non-ferrous exhibition—CHINA DIECASTING & CHINA NONFERROUS 2026 (Shanghai New International Expo Center, Halls N1-N4) from July 15-17, 2026, at Booth N4B33 (Magnesium Alloy Casting Zone). Under the theme "Twin Engines: Al & Mg, A Lightweight Future", this edition is expected to span 49,200 square meters, feature 600+ exhibitors, and attract 28,000 professional visitors. Enterprises and professionals from the global die-casting and non-ferrous casting industry chain are welcome to visit for exchange and cooperation.
