Press release
Fraunhofer Germany to Present Multiple Cutting-Edge Non-Ferrous Casting Technologies in July Shangha
The Fraunhofer-Gesellschaft is Europe's leading applied research and development organization. With more than 70 institutes and research units in Germany and around the world, it is dedicated to conducting solution-oriented research for industry, the economy, and society. One of its key focus areas is casting technologies for the production of aluminum, magnesium, or steel castings.
From July 15 to 17, four Fraunhofer institutes will jointly participate in CHINA DIECASTING & CHINA NONFERROUS 2026.
Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM – Core focus areas: high-pressure die casting, low-pressure die casting, and adhesive bonding technology for castings, with a strong emphasis on process stability and material compatibility.
© Fraunhofer IFAM
Fraunhofer Institute for Casting, Composite and Processing Technology IGCV – Focused on permanent mold casting, low-pressure die casting, and sand 3D printing, with deep expertise in the combination of complex casting forming and additive manufacturing.
© Fraunhofer IGCV
Fraunhofer Institute for Structural Durability and System Reliability LBF – Specializing in the service performance evaluation of castings, including fatigue durability, damage tolerance, and system reliability optimization.
© Fraunhofer LBF
Fraunhofer Institute for Laser Technology ILT – Core focus: application of Extreme High-Speed Laser Material Deposition (EHLA) technology in the coating, repair, and prototyping of forming tools made of tool steel (hardness > 68 HRC).
© Fraunhofer ILT
Ten Exhibits Focusing on the Substance of the Technology
The booth will feature physical samples and process comparison specimens from the participating institutes, highlighting verifiable technological achievements:
Technical Presentations – Face-to-Face with R&D Leaders
During the exhibition, technical experts from Fraunhofer institutes will share specific research findings:
July 15, 11:15–11:40
International Die Casting Market Development Seminar
Topic: High-Pressure Die Casting vs. Low-Pressure Die Casting
Speaker: Christoph Pille, Director of Casting Technology, Fraunhofer IFAM
July 16, 11:00–11:30
International Automotive Lightweighting Development Forum
Topic: Research on Durability and Reliability Improvement for Lightweight Automotive Castings
Speaker: Dr. Christoph Bleicher, Head of the Innovation, Technology Transfer and Cooperation Department, Fraunhofer LBF
Technology Transfer Opportunities
IFAM
>> Casting Cores and Sand Mold 3D Printing
About CHINA DIECASTING & CHINA NONFERROUS 2026
CHINA DIECASTING & CHINA NONFERROUS 2026 will be held from July 15 to 17 at the Shanghai New International Expo Centre (Halls N1–N5). As Asia’s largest die casting and nonferrous casting exhibition, this edition features the theme “Twin Engines: Al & Mg, A Lightweight Future”. The exhibition is expected to cover 52,000 sqm of display space, attracting 650+ exhibitors and 28,000+ professional visitors, covering OEMs, robot manufacturers, Tier 1 suppliers, foundries, and key players in the supply chain including equipment and material suppliers.
From July 15 to 17, four Fraunhofer institutes will jointly participate in CHINA DIECASTING & CHINA NONFERROUS 2026.
Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM – Core focus areas: high-pressure die casting, low-pressure die casting, and adhesive bonding technology for castings, with a strong emphasis on process stability and material compatibility.
© Fraunhofer IFAM
Fraunhofer Institute for Casting, Composite and Processing Technology IGCV – Focused on permanent mold casting, low-pressure die casting, and sand 3D printing, with deep expertise in the combination of complex casting forming and additive manufacturing.
© Fraunhofer IGCV
Fraunhofer Institute for Structural Durability and System Reliability LBF – Specializing in the service performance evaluation of castings, including fatigue durability, damage tolerance, and system reliability optimization.
© Fraunhofer LBF
Fraunhofer Institute for Laser Technology ILT – Core focus: application of Extreme High-Speed Laser Material Deposition (EHLA) technology in the coating, repair, and prototyping of forming tools made of tool steel (hardness > 68 HRC).
© Fraunhofer ILT
Ten Exhibits Focusing on the Substance of the Technology
The booth will feature physical samples and process comparison specimens from the participating institutes, highlighting verifiable technological achievements:
- Lightweight castings optimized through topology optimization and fatigue assessment, with direct comparison against non-optimized parts;
- A series of fatigue test specimens covering welded fatigue of high-pressure die-cast aluminum, corrosion fatigue, and internal defect susceptibility assessment;
- fusionCASTING overlap specimens, demonstrating the direct composite forming process combining high-pressure die casting and aluminum sheets;
- E-drive inverter housing with low-pressure cast salt cores embedded in the high-pressure die-cast housing, enabling internal flow channel integration;
- BioniCast cooling tube integrated casting, with filler-free cooling tubes cast directly into the aluminum component to enhance heat exchange efficiency;
- High-purity aluminum (99.7%) high-pressure die-cast coil, designed for high-performance e-drive applications;
- Carbon fiber–cast aluminum hybrid material bracket, achieving direct bonding of dissimilar materials during the die-casting process;
- Laser-deposited metal wear-resistant coatings on casting mold surfaces;
- Binder jet 3D-printed specimens using pure aluminum powder, along with process improvement comparisons demonstrating the elimination of stair-stepping effects through binder concentration adjustment;
- Ceramic cores with predetermined fracture points, showcasing the controlled fracture design of 3D-printed ceramics in complex internal cavity forming.
Technical Presentations – Face-to-Face with R&D Leaders
During the exhibition, technical experts from Fraunhofer institutes will share specific research findings:
July 15, 11:15–11:40
International Die Casting Market Development Seminar
Topic: High-Pressure Die Casting vs. Low-Pressure Die Casting
Speaker: Christoph Pille, Director of Casting Technology, Fraunhofer IFAM
July 16, 11:00–11:30
International Automotive Lightweighting Development Forum
Topic: Research on Durability and Reliability Improvement for Lightweight Automotive Castings
Speaker: Dr. Christoph Bleicher, Head of the Innovation, Technology Transfer and Cooperation Department, Fraunhofer LBF
Technology Transfer Opportunities
IFAM
- Composite casting forming processes: combined pouring of aluminum sheets and castings
- Lost core technology: salt cores and sand cores for high-pressure die casting
- Sensor embedding processes: novel castings for autonomous vehicles
- Adhesive bonding and welding technologies: joining of high-pressure die-cast components for body-in-white and mega castings
- Reliability assessment and life prediction: reliable life calculation solutions for safe, sustainable, and cost-effective products
- Early-stage risk identification for robust design of materials, components, and systems
- Dynamics and vibration engineering
- Product validation and prototype development
- Sustainability and circular economy: development of resource-efficient metal and plastic products based on the full life cycle concept
>> Casting Cores and Sand Mold 3D Printing
- Binder performance testing and zero-series specimen development
- Process analysis (dimensional accuracy of sand molds and cores, process defect investigation, process improvement potential identification)
- Printhead performance analysis
- Complete line equipment development
- Plant layout planning and full process flow planning
- In-process monitoring – cost estimation and life cycle environmental balance assessment
- Full-process casting simulation
- Prototype development of aluminum, copper, and iron castings
- Development of hybrid composite materials
- Value stream analysis
- Process data management
- Sensor technology for casting processes
- Application of Extreme High-Speed Laser Material Deposition (EHLA) technology in the coating, repair, and prototyping of forming tools made of tool steel (hardness > 68 HRC).
About CHINA DIECASTING & CHINA NONFERROUS 2026
CHINA DIECASTING & CHINA NONFERROUS 2026 will be held from July 15 to 17 at the Shanghai New International Expo Centre (Halls N1–N5). As Asia’s largest die casting and nonferrous casting exhibition, this edition features the theme “Twin Engines: Al & Mg, A Lightweight Future”. The exhibition is expected to cover 52,000 sqm of display space, attracting 650+ exhibitors and 28,000+ professional visitors, covering OEMs, robot manufacturers, Tier 1 suppliers, foundries, and key players in the supply chain including equipment and material suppliers.
