Albert Handtmann Metallgusswerk GmbH & Co. KG
Handtmann pioneers die-cast aluminium wheels
High-pressure die casting enables lighter wheels with improved CO2 performance and driving dynamics
Albert Handtmann Metallgusswerk GmbH & Co. KG has developed its die-casting processes to enable, for the first time, the production of complete aluminium wheels using high-pressure die casting (HPDC). The new light-performance wheels are up to 20 percent lighter than conventional low-pressure die-cast wheels, opening a market segment previously considered unattainable for HPDC. With this step, the Handtmann Group positions itself as a full-range solution provider for lightweight aluminium components and sets new benchmarks for the wheel and automotive industries. OEMs, wheel manufacturers, fleet operators and end customers benefit from a reduced CO₂ footprint, enhanced driving dynamics and significantly greater design freedom. In battery-electric vehicles, the reduced wheel mass also contributes to a measurable increase in driving range. The new aluminium wheels will make their public debut at Euroguss 2026 in Nuremberg. Series production readiness is planned for the course of 2026.
The newly developed casting system demonstrates Handtmann’s comprehensive development expertise in the light-metal industry. The entire process—from the initial concept through the design of the casting system to series production—was developed and implemented in-house. The wheel blanks are produced in series using HPDC at Handtmann. Subsequent processes such as machining, coating and quality assurance are carried out by the partner company Cevher Group, which has decades of experience in the wheel industry. Both partners have aligned the complete process chain to the requirements of the automotive industry. “By introducing this technology, we are opening the automotive wheel segment to high-pressure die casting for the first time and, at the same time, laying the foundation to transfer this process to other components in the future. This allows us to set new standards in both the light-metal and automotive industries,” says Dirk Seckler, Co-CEO of Handtmann Leichtmetallguss.
HPDC as a key technology for efficient wheel production
At the core of the innovation is high-pressure die casting, a process long established for the cost-efficient production of large-volume aluminium components. For the first time, Handtmann is applying HPDC to the manufacture of complete aluminium wheels—until now a domain reserved exclusively for low-pressure die casting.
In HPDC, molten aluminium is injected into a precisely engineered die under very high pressure within milliseconds and solidifies under applied pressure. This enables the production of complex, thin-walled components with high dimensional accuracy and excellent surface quality in large volumes. Short filling times, high clamping forces and automated process control ensure high productivity, while near-net-shape casting reduces the need for downstream machining.
For Handtmann, HPDC therefore forms the basis for manufacturing structurally relevant aluminium components such as wheels with high productivity at scale. At the same time, the process supports OEMs and wheel manufacturers in reducing CO₂ emissions and realising aerodynamically optimised designs.
New design freedom for OEMs
Reducing CO2 emissions is a key objective for vehicle manufacturers, both in production and during vehicle operation. The new HPDC wheel addresses these requirements through lower mass and aerodynamically optimised geometries that reduce air resistance and increase vehicle range, particularly in electric cars. “Thanks to the enhanced design freedom offered by HPDC and the minimal distortion inherent in the die-casting process, we can realise wheel designs that were simply not feasible with conventional methods. This will appeal equally to designers and car enthusiasts. In addition, the often-required aerodynamic cover becomes unnecessary, further reducing weight and cost,” says Andreas Würzer, Head of Technical Development.
Advantages for end customers and fleet operators
End customers benefit from a lightweight wheel that improves handling through reduced unsprung mass. The combination of attractive design, enhanced driving dynamics and more sustainable production increases overall vehicle performance. Fleet operators—including logistics providers, car-sharing services and corporate mobility fleets—also benefit from the efficiency gains. Lower energy or fuel consumption improves operating costs, while the improved CO₂ balance can be directly leveraged for sustainability reporting and certification requirements.
Further information:
Albert Handtmann Metallgusswerk GmbH & Co. KG
Isabel Jeschek
Head of Market Strategy & Communication
Arthur-Handtmann-Str. 25-31
88400 Biberach/Riss
Phone +49 7351 342-6405
Isabel.jeschek@handtmann.de
www.handtmann.de
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The Handtmann Group
The Handtmann Group is a globally active technology company in the processing industry with around 4,700 employees, 3,300 of whom are based at its headquarters in Biberach an der Riß, Germany.
Cutting-edge technology, innovation and a people-oriented approach are at the heart of this family-run company. The group is divided into five business divisions with autonomous management structures: light metal casting, system technology, processing, plant engineering and plastics technology. At the top of the group of companies is a holding company that acts as a management, financing and investment company.
Handtmann generated sales of 1.3 billion euros in 2024. Thanks to a consistent policy of reinvesting profits, the company owners are able to make substantial investments in research and development as well as production facilities. In this way, the founding family provides long-term support for qualitative growth.
The group of companies is currently represented in more than 100 countries with its own production facilities, branches and factory representatives. Founded in 1873 as a brass foundry, the Handtmann group of companies celebrated its 150th anniversary in 2023.
Light metal casting division
As part of the group of companies, the Light Metal Casting Division is a strategic partner for the development and manufacture of aluminium solutions, thanks to its extensive expertise in development, prototyping, materials science, die casting and post-processing. Handtmann is the first European Tier 1 supplier to manufacture structural parts using the emerging megacasting process and is a relevant partner for innovations and technologies in the automotive industry.
The subsidiary is the largest light metal foundry in Europe with several locations in Germany, Slovakia and China, and acts as a global partner for its international customers.
https://www.leichtmetallguss.handtmann.com/en
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