System change with significant reduction in CO₂ emissions
For the Swedish manufacturing industry to achieve net zero, a comprehensive transition is required, not least in the automotive industry. One of the first strategic projects within Net Zero Industry, EFFECT – Efficient Resource Utilisation in Casting Technology, brings together several leading players to take the next step towards a sustainable, circular and high-performance die-casting system based on aluminium.
EFFECT started its first phase during Net Zero Industry’s first year, 2024. In November last year, the project entered phase 2, which focuses on developing a system demonstrator for a resilient, resource-efficient and digitalised value chain for high-pressure die casting (HPDC).
A complex system that requires shared knowledge
Today’s vehicles are often built from a large number of press-formed sheet metal parts that are produced and transported between many suppliers before being assembled into complete body parts. The fragmented chain poses both quality challenges and significant CO₂ emissions. Through functional integration and large structural die-cast components, the manufacturing chain can be significantly simplified, while reducing environmental impact. The EFFECT project partners see a great need to jointly develop new knowledge about aluminium die casting and how the technology can be scaled up in Sweden.
Joint research initiative to fill knowledge gaps
During the first stage, it quickly became clear to the project that Sweden lacks sufficientresearch in several areas related to large-scale die casting, particularly in the fields of materials technology and recycled aluminium. The focus of phase 2 is therefore on knowledge gaps in materials technology, design methodology, process optimisation, digitalisation and system-level issues. The project also includes the development of a digital infrastructure, advanced AI-supported concept design and strategies for a circular material supply based on secondary aluminium.
By bringing together industry, academia and research institutes, the project creates a common platform for building the knowledge required for system change and integrating technology, business models and regulations into a coherent whole. This is a transition that cannot be driven by individual actors; by working together, the parties can both broaden their perspectives and accelerate development.
Die casting as an enabler for major climate gains
One of the project’s central tracks concerns how a transition to die-cast vehicle parts can reduce climate impact. The long-term goal is to use recycled aluminium to a large extent in order to significantly reduce CO₂ emissions compared to today’s solutions. However, this requires further research, particularly into alloys and material properties.
Focus on system challenges – not just technology
EFFECT analyses key system challenges that must be solved in order for Sweden to scale up sustainable die casting:
- digitisation and interoperability through a new shared data and knowledge platform
- faster and more accurate concept design loops supported by AI and advanced simulations
- increased use of secondary aluminium through improved material quality and process control
- development of cost-effective and sustainable tool technologies
- strategies for Swedish and European material supply and regulatory compliance (CSRD, IED 2.0, SSbD)
Benefits far beyond the automotive industry
Although the project has strong links to the automotive industry, the partners believe that the results will be relevant to many other industries. Die casting is already used in the telecoms sector, for example, and all industries with large volumes can benefit from the knowledge built up within EFFECT.
Aboute EFFECT
Project owner:
Volvo Cars
Project manager:
RISE
Project participants: AGES, Bryne, Chalmers, Comptech, Keysight Technologies, Radalytica, Stena Aluminium, Swedish Foundry Association, Swedish Aluminium, Jönköping University of Technology, Thermo-Calc Software, Traton AB, Volvo Technology AB