6 Influential Trends Shaping the Future of the Metal Casting Industry

Megan R. Nichols,
Freelance Technical Writer

Every industry experiences change, big or small, as the world itself transforms thanks to discoveries, new technologies and more efficient operations. The die-casting and metal casting industry is no exception. Thanks to some rather quick-moving trends, it certainly seems as if metal casting will evolve more rapidly in the coming years.

A few things are happening currently that will likely shake the field's foundations, hopefully for the better.

1. Automation Will Be Crowned King

Foundries are dangerous even when they’re intelligently designed and well-maintained. Metal casters and manufacturers will more often rely on automation and advanced machinery to alleviate some of that danger and remain highly competitive.

Automation systems can vastly improve productivity and output while maintaining a high degree of precision and quality. Moreover, besides malfunctioning equipment — which can be eliminated by establishing proactive maintenance and care policies — automation hardware never grows tired, and it never burns out, unlike human laborers.

This frees up workers to spend more time on testing, implementation and product designs. It also improves a general operation, bolstering the reputation of the company or brand.

A fortunate side effect is that metal casters can better prepare for and deal with labor shortages. The push for more modern equipment will also bring in new blood interested in working with the latest technologies.

2. Alternatives Will Continue to Displace Steel

Steel has been the go-to material for most projects and components, and it’s been this way for decades. However, because of its weight, the material is being overshadowed by lighter alternatives, like aluminum. Magnesium and Zinc are also excellent alternatives, thanks to their strength and lightweight properties.

We’re seeing this happen in the automotive and aerospace industries especially, but it’s also happening in enterprise and consumer electronics. Brass is an excellent example, as well, thanks to its high corrosion-resistance and unrivaled conductivity properties. Brass casting is becoming more prevalent. This can be attributed to it's smooth, easily-adjustable surface finish, high production opportunities, and enhanced dimension controls.

Thanks to more advanced manufacturing methods resulting in pure and high-quality metal alloys, some of the alternatives have jumped to the top of the demand list, aluminum included. This will continue to happen, and it’s due to the rise in aluminum and continuous cast-iron applications.

3. Industry 4.0 Is Here

The manufacturing industry has already embraced smart technology, implementing more digitized processes in a larger push toward Industry 4.0. Smart sensors and connected machines are being adopted, and they’re also being driven and controlled by data-oriented systems.

AI, big data and machine learning solutions will analyze troves of incoming information, in real-time, to make decisions on the fly. They can adapt operations and machinery to match market trends. Output can instantly be scaled up or down to meet market demands. Malfunctioning or questionable machinery can be repaired or pulled from the lineup before major impactions occur in the supply chain. Also, new and more advanced development and assembly methods can be discovered and implemented at much faster rates.

Beyond smart technology, there are other innovative solutions taking hold, like virtual reality. VR allows metal casters to realize true-to-life models in a digital environment. Augmented reality, an offshoot of VR, can help workers by superimposing images or virtual schematics in the real world.

4. Additive Manufacturing Is Serious Business

When it first appeared, 3D printing — or additive manufacturing as it’s known in the commercial world — was extremely limited compared to traditional methods. That is no longer the case. The technology is being used to work with dozens of different materials, metal included. It’s also creating more precise, larger, and high-quality components and products.

The technology can print entire structures, such as two-story administrative building,a so commercial-grade metalwork is no problem. Moreover, many items that are complex and difficult to produce using regular casting methods are a cinch for additive printers.

Adopting these technologies will eat up some of the metal casting markets, especially for smaller projects, regardless of scope. It’s something all metalworking manufacturers will have to get on board with, like it or not.

5. It’s Time to Go Green

It’s no secret that foundries, factories and manufacturing plants make up some of the most energy-demanding operations in the commercial world. If nothing changes, the industry will become more detrimental to the environment and continue to release harmful greenhouse gases.

Most industries have already implemented eco-friendly and green initiatives, and the entire manufacturing world is long overdue. It is possible to shift toward renewable energy sources, improved waste production and handling, and higher-efficiency operations. The latter especially is within reach, merely by adopting more efficient casting molds and technologies to reduce energy requirements and cut down on raw material usage. Many foundries have already adapted and effectively used recycled materials, but high energy usage remains a problem.

6. The World Market Is Anomalous

COVID-19, a massively adjusted supply chain, trade conflicts between China and the U.S. and materials shortages are currently affecting the world market. One thing is certain: No one knows where this is headed or what will arise after these events. Supply chains will likely be disrupted and may even grind to a halt in some cases. The prices of raw materials will continue to climb. Logistics and handling may become more difficult than ever in the wake of labor shortages, a pandemic and much more.

Manufacturers, including metal casters, will need to be more flexible than ever. Unfortunately, there doesn’t appear to be a lull in sight. Everyone in the field will need to stay on their toes.

The Times, They Are a-Changin’

The world is a very different beast these days, and many of the events playing out are impacting the commercial sector as a whole, including metalwork operations. COVID-19, for example, has put a damper on the modern way of life and business.

Automation, more efficient materials, smart technology, additive manufacturing and eco-friendly requirements are just a few of the trends shaping the future of metal casting. It’s also important to realize that, while these trends are the most relevant right now, the market is dynamic and there are many more to come. Above all, flexibility is perhaps one of the most important requirements for metal and die casting operations, if only to keep up with the changing times.