Carat Megacasting by Bühler Group: status and timeline

Milestones

No announced next step

Casting defects in large partsShrinkage porosity, gas porosity and incomplete filling are harder to control in large structural castings than in small dies.
Capital cost per installationEach Carat cell costs ~CHF 10 million; carmakers must justify the investment against stamped-and-welded alternatives.

Part size limitsEven at 92,000 kN, die cavity size is limited. The largest single-piece parts are roughly 2 meters in the longest dimension; larger structures require multiple castings and assembly.
Metal flow in complex geometriesThin walls and tight radii are hard to fill without defects. Designers must balance structural needs with castability.

3 parts

Die cavity

The die cavity is designed for a specific part shape, and molten metal fills it under high pressure. Dies are custom-made for each part geometry.

Pressure and speed

Carat applies pressure up to 92,000 kN to pack metal into the cavity, reducing porosity and voids that would otherwise appear in castings.

Cooling

Metal solidifies while in the die, which dissipates heat and controls microstructure. The cycle time is typically 2–4 minutes per part.

Spec	Carat Megacasting
Maximum clamp force	Up to 92,000 kN^R (reported)
Systems shipped	50^R (reported)
Approximate total order value	CHF 500M^R (reported)

^R reported by the company

1 update

The team behind Carat Megacasting

Bühler Group

Carat megacasting, grain milling, process engineering

Swiss manufacturing-equipment maker. Grain milling, animal feeds, die-casting machines. Carat gigacasting presses for automotive.

50th Carat order reached from six of the world's top 10 carmakers.
Presses cast battery frames, underbodies, and large structural parts in aluminum and magnesium.
Pressures up to 92,000 kN; ~CHF 10M per system.

Founded: 1860166 yrs
Headquarters: Switzerland
Status: Private
Valuation: private
Staff: ~12,090
Works in: ManufacturingGigacasting
Coverage: 1 program · 1 updatelatest 1 Jan 2024checked 11 Oct
Customers: Volvo (opens volvogroup.com)Honda (opens honda.com)GF Casting Solutions (opens gfautomotivecasting.com)
People: Samuel Schaer (opens buhlergroup.com)CEOStefan Scheiber (opens buhlergroup.com)Chairman

Spec

Carat Megacasting

Maximum clamp force

Up to 92,000 kN^R (reported)

Systems shipped

50^R (reported)

Approximate total order value

CHF 500M^R (reported)