Volvo Cars has taken a significant step in automotive manufacturing innovation by purchasing two Carat 840 die-casting cells from Bühler for its Torslanda plant in Sweden. These high-pressure machines, capable of 84,000 kN locking force, enable the production of massive single-piece aluminum castings—known as “megacastings”—that can replace up to 100 traditional car body components. The move positions Volvo among the first automakers to embrace this transformative production method.
Bühler Expands Market Leadership with Carat Series
The Carat 840 and its larger sibling, the Carat 920 (92,000 kN), represent the latest evolution of Bühler’s die-casting technology, building on the success of earlier models introduced in 2020. With over 90 years of experience in die-casting, the Swiss company now dominates the structural casting market, with half of all automotive “body in white” components reportedly produced on Bühler machines. “Our complete cell solutions address every aspect from melting furnaces to final part handling,” said Cornel Mendler, Managing Director of Bühler Die Casting.
Megacasting Revolutionizes Auto Production
This technology breakthrough offers automakers multiple advantages: dramatically simplified assembly processes, reduced vehicle weight, and lower carbon footprints when using sustainable aluminum alloys. The integrated approach allows castings to be produced near assembly lines, minimizing logistics while enabling immediate recycling of excess aluminum within the production cell. “Megacasting gives structural casting another push by extending applications to complete body sections,” Mendler explained, noting its growing importance across the industry.
Sustainability Benefits Drive Adoption
Beyond production efficiency, megacasting supports environmental goals. Aluminum components can approach carbon neutrality when manufacturers use low-CO₂ alloys and biogas-powered furnaces. The weight reduction from aluminum parts also decreases energy consumption throughout a vehicle’s lifecycle. Bühler’s closed-loop system, which remelts overflow aluminum on-site, further enhances the sustainability profile by eliminating transport emissions associated with recycling.
Setting New Standards in Automotive Manufacturing
Volvo’s investment signals confidence in megacasting as the future of auto manufacturing. As more automakers consider adopting this method, Bühler’s complete solution approach—combining machinery, expertise, and global service support—positions the company as the go-to partner for this industrial transformation. The Carat series’ ability to produce ever-larger structural components continues to redefine what’s possible in vehicle design and production efficiency.
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