EFFECT – Efficient use of resources in casting technology

The project represents the second phase of a mission‑driven initiative aimed at transforming Sweden’s aluminium high‑pressure die casting (HPDC) industry toward circular, resilient, and net-zero manufacturing. Building on the feasibility study conducted in EFFECT (Phase 1), this phase focuses on developing a system demonstrator for HPDC of large, structurally integrated aluminium components produced from recycled material.

The project addresses key industrial challenges such as material efficiency, process optimization, digitalization, and industrial interoperability. Through advanced tooling technology, AI‑supported design and inspection, and an integrated digital data infrastructure, the consortium will develop a robust value chain that strengthens Swedish industrial competitiveness and drives the green transition. The project also contributes to the foundation for the Center for Sustainable Casting (CSC), a national innovation hub for collaborative testing, education, and development within sustainable casting technologies.

The overall objectives are to reduce CO₂ emissions and material losses, improve process stability and cost efficiency, and ensure compliance with EU climate and sustainability requirements.

The work is organized into four work packages:

• WP1 – Sustainable Design
  Development of circular design principles and AI‑supported methods for integrated HPDC components.
• WP2 – Sustainable Process Technology
  Optimization of HPDC processes for recycled aluminium, including tool durability, material flows, and energy efficiency.
• WP3 – Digitalization and AI
  Development of digital infrastructure, digital twins, and AI models for design, process control, and inspection.
• WP4 – System Demonstrator
  Validation in an industrial environment through the demonstration of a fully integrated, digitally enabled, and sustainable HPDC value chain.

The project is carried out in close collaboration between industry, academia, and research institutes, resulting in guidelines, methods, and digital tools that enable a circular, climate‑neutral, and competitive Swedish aluminium casting industry.

This is the second stage of the project. Read more about the first stage here.