Going beyond limits in sustainable mobility

How can we reduce fuel consumption and greenhouse gas emissions while continuing to support an increasingly mobile society? An answer to this modern challenge is one of the most important success factors for sustainable mobility: by making vehicles lighter.

Transportation accounts for 23% of global energy-related CO2 emissions, according to the OECD’s ITF Transport Outlook 2023. The construction of vehicles, the building of transportation-related infrastructure and fuel production also result in GHG emissions. Yet, as populations and economies grow, so does the demand for freight and passenger transportation.

From cars to planes to commercial trucks: the heavier they are, the more energy they consume and the more harmful emissions are released into the atmosphere. Building lighter vehicles improves their energy efficiency while reducing their environmental impact.

Yet, cars have become heavier by almost 40% between 1975 and 2000, says a 2017 ITF study. However, if the average mass of passenger cars gradually decreased from 1’400 kg today to 1’000 kg in 2050, and the weight of light commercial vehicles decreased from from 1’800 kg today to 1’100 kg during the same period, it would be possible to cut their CO2 emissions by almost 40%, compared to a 1990 baseline, says the same study.

Advanced manufacturing techniques are essential in the effort to develop sustainable ways of moving people and goods.

Thanks to long-standing experience and its innovation capabilities, GF Casting Solutions has been a pioneer in the development and production of large structural components for the automotive industry. Specifically, by integrating more functionalities into single cast components and reducing the number of individual parts to be assembled. Beyond simplifying the manufacturing processes, such components reduce vehicle weight and improve the performance of the part. This helps cut CO2 emissions in production and in fuel consumption during the use of the vehicle.

Big castings mark a paradigm shift in the automotive industry and are set to transform supply chains and production, but are also posing some challenges for established processes and logistics. With its longstanding experience, GF Casting Solutions has become a development partner of choice to help find the right answers.

“Our customers are very demanding in terms of safety, quality and innovation”

Christoph Stapf, Vice President Sales for GF Casting Solutions

“Collaborating closely with the automotive industry gives us the opportunity to contribute to the development of a more sustainable transportation industry, which is essential to the global economy and to society as a whole.”

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Future-proofing mobility

In 2023, GF Casting Solutions won its biggest-ever order, placed by automaker BMW. This order for large structural castings is pushing the boundaries of current technologies on several fronts, including dimensions, functionality and performance. The lightweight components will be used in a vehicle line that will be offered with a variety of drive trains, such as hybrid and full electric.

“GF’s ability to innovate in die casting is one of the key points to the success of this project,” said Frank Wimmer, Purchasing BMW Light Metal Casting. “But it’s not just technical expertise that we value. The GF team knows how to collaborate, share ideas and think holistically about tough challenges.”

GF and BMW started working together closely early in the process, from part design and simulation to tool development and production, as well as ongoing testing and validation of the casting components.

The transportation sector is undergoing a fundamental transformation. GF Casting Solutions has been fostering innovation in the foundry industry for centuries. As a result, it is uniquely well positioned to support the industry’s shift toward a more sustainable future by supporting customers in developing innovative solutions that are shaping the mobility of tomorrow.

Q&A with Christoph Stapf from GF Casting Solutions

Christoph Stapf

Vice President Sales,
GF Casting Solutions

How does GF Casting Solutions help its customers contribute to greater sustainability?

Our customers are gradually raising their expectations regarding sustainability. In this respect, all our products are 100% recyclable, and our expertise is crucial in two main areas. Firstly, we provide solutions that are not only lighter but also come with enhanced functionalities, improving the sustainability performance of vehicles during their use. Secondly, we contribute to resource conservation throughout the entire manufacturing process, both at our facilities and our customers’ sites – significantly reducing the CO2 footprint.

How has GF contributed to a successful relationship with BMW?

We have collaborated with BMW for more than 20 years, starting with the development of the first HPDC shock tower and reaching start of production in 2003. The partnership is on an equal footing, which allows us to engage in new projects early on. We have evolved into an innovation and R&D partner across the entire value chain; from the concept phase to industrialization, unlocking the full potential of our shared ideas. Ultimately, this results in a competitive advantage for our customer in the market.

What makes you personally proud to work at GF and in this project in particular?

Being actively involved in the development of an exciting vehicle within the BMW line-up truly stands out. We are currently engaged in an intercontinental project, collaborating with BMW across all regions. My team is in daily contact with the BMW team. Witnessing how this product comes to life really makes me proud to work at GF.