1. ACTech
  2. Industries Served
  3. Giga Castings

GIGACASTING WITHOUT COMPROMISE

In a dynamic and ever-evolving industry shaped by constant change and new challenges, we meet our customers' demands with innovative solutions. 

At ACTech, we are always one step ahead and fully prepared for the future. 

Recognizing the growing demand for huge and precise cast components early on, we have continuously expanded our expertise in this field.

Alongside our established core business, we focus on the production of Gigacastings—large- structural cast components that integrate multiple parts into a single piece. We manufacture these castings with just one pour, without compromising on speed or quality. Our Gigacasting prototypes are produced using sand casting, offering properties and quality seen in serial production 

Our team is already where our customers will need us tomorrow—always one step ahead and ready for the future.

  • For prototype manufacturing in the automotive, construction machinery, commercial vehicle, shipbuilding, and other future industries, large  castings with tight dimensions are often required.
  • Time is of the essence and the demand for large, light and functional prototypes that mirror serial production quality is increasing.
  • Gigacastings require cutting-edge technology, the highest precision, and extensive manufacturing expertise.

 

ONE STEP AHEAD WITH ACTECH

At ACTech, we take pride in constantly redefining the limits of what is possible. We recognized the growing demand for prototypes of increasingly larger and more complex components early on. In recent years, we have made significant investments in this field, ensuring that our production facilities are now optimally equipped for the manufacturing of Gigacastings.

This technical expertise is complemented by a highly professional team and outstanding project management. Our customers are supported throughout the entire project lifecycle, consistently exceeding expectations. With our specialized processes – from optimized cooling techniques and targeted heat treatments to custom alloys – we overcome any manufacturing challenge. Additionally, our in-house machining capabilities and testing procedures are specifically tailored to the unique requirements of large-scale components.

When you go “all in” with ACTech, you stay one step ahead. We cover the entire process chain, from design to transport – wherever you are, ACTech is right there with you.

Our capabilities

GIGACASTING: UNLIMITED POSSIBILITIES

Gigacastings unlock unlimited design potential. Our innovative manufacturing processes push traditional boundaries, taking creative freedom to the next level!

Our sand casting process enables the production of complex, thin-walled, and large structural casting components – a crucial step in prototype development before transitioning to series production. When it comes to manufacturing large-scale structural components, ACTech is the right partner to bring your vision to life.

Certificates for GIGACASTING

Our comprehensive quality assurance system accompanies every step of the entire production process. In addition, our quality and environmental management systems are certified by TÜV SÜD Management Service GmbH according to ISO 9001 and ISO 14001.

Need heavy-duty components that withstand the unique challenges of the maritime industry? No problem – ACTech is certified by DNV as an "Approved Manufacturer for Iron Castings in the Ship and Offshore Sector."

Our certificates

FAQ

What are Gigacastings?

What are Gigacastings?

Gigacastings are exceptionally large and complex cast components with extremely thin walls. They are designed for future die-casting production. By utilizing state-of-the-art prototyping technologies and specialized manufacturing techniques, these components can be produced with extreme precision and complexity—without compromising on quality or speed.

What is the maximum size and weight ACTech can produce for large structural castings? 

What is the maximum size and weight ACTech can produce for large structural castings?

 

We have successfully manufactured components in a wide range of sizes and prefer not to set strict limitations. Currently, ACTech can produce cast parts up to 4 meters in size and 1.5 tons in weight—and we’re always pushing the boundaries of what’s possible!

How does ACTech ensure the quality of such large and/or heavy components? 

How does ACTech ensure the quality of such large and/or heavy components?

 

We’ve developed and rely on several specialized processes, from cooling techniques to heat treating and custom alloys. Additionally, all our products undergo rigorous quality controls throughout the entire production process to ensure the highest standards.

How are Gigacastings transported to the customer? 

How are Gigacastings transported to the customer?

 

At ACTech, we provide specialized logistics solutions, ensuring that cast components – including large-format parts – are delivered safely and on time worldwide. We pay attention to every detail, using custom packaging such as cartons, pallets, or wooden crates to guarantee the safety of your component.

What are typical applications of Gigacastings? 

What are typical applications of Gigacastings?

 

Large- structural cast components are used across a wide range of industries and applications, including automotive, aerospace, marine, and the energy sectors. Particularly in the auto industry, new requirements such as weight reduction and space optimization are driving the demand for thin-walled, lightweight, and highly complex components.

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