Costamp Group took part in Car Body Parts 2026, the congress organized by Automotive Circle dedicated to materials, technologies, manufacturing and forming processes for the future of automotive components.
During the session focused on mega-casting and structural HPDC, our colleague Antonio Stefanoni contributed as a speaker with the presentation:
“The die maker’s strategic role in mega-casting part design”
The central theme of the speech was the increasingly strategic role of the die maker in the development of mega-casting components, but not only, within an industrial context where the market demands faster development times, greater efficiency and cost reduction from the earliest design stages.
In the field of mega-casting, the complexity of structural components requires a different approach compared to traditional processes. It is no longer only a matter of designing a die after the product has been defined, but of integrating HPDC know-how and tooling expertise from the concept phase, helping to turn months of development into weeks through experience, full team commitment and clear accountability at every project milestone.
One of the key points of the presentation was the shift from serial development to parallel development, where product owners, concept engineering, R&D, process engineering, plants, purchasing, Tier 1 suppliers and tool makers work in a coordinated way from the earliest stages. This approach makes it possible to anticipate critical issues, align technical constraints, costs and objectives and reduce the gap between design intent and manufacturing reality.
The early involvement of the HPDC partner and direct dialogue between die makers and Body In White designers therefore become fundamental elements to improve component manufacturability, optimize geometry, increase process efficiency and support the industrial feasibility of increasingly integrated and complex solutions.
Open and transparent collaboration between OEMs, BIW designers and die makers is essential. Collaborating, challenging conventional limits and innovating together creates the conditions to develop mega-casting components that are not only technologically advanced, but also robust, feasible and suitable for series production.
This approach reflects Costamp Group’s vision as a technology partner able to support customers throughout the entire development process, combining engineering, simulation, tooling and manufacturing expertise to contribute to the creation of advanced solutions for lightweight, efficient and sustainable mobility.
We would like to thank Automotive Circle for the opportunity to contribute to such a high-level technical exchange and Klaus Hansen of ODIN CASTING SOLUTIONS for presenting the topic together with us.
