Weekly Gigacasting News 37

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LK Group has partnered with Shenzhen Cyborg Robotics, Shenyang Foundry Research Institute, Fujian Magnesium Casting Lightweight and Suzhou Saifeis New Materials Technology specializing in magnesium alloys and humanoid robot R&D to launch a strategic joint research and development initiative.

This collaboration focuses on advancing magnesium alloy applications in humanoid robots, aiming to overcome longstanding challenges in traditional robotics, particularly weight and strength constraints, through the creation of lightweight, high strength components that boost overall performance and manufacturing efficiency.

The consortium will establish a dedicated "Joint R&D Center for Humanoid Robot Components", with emphasis on critical technical domains such as magnesium alloy shell molding, process optimization, and innovative lightweight structural design.

LK Technology will leverage its core expertise in die casting and magnesium thixomolding, supplying cutting edge equipment and process innovations to drive breakthroughs in lightweight robot architectures. I would image that LK will utilize a die casting machine equipped with a TPI module to contribute to this project.

Why does it matter?

Magnesium alloys can slash the weight of cast motor shells by over 30% compared to equivalent aluminum parts. For humanoid robots, a similar reduction in structural components, especially in arms and legs, could dramatically lower power consumption.

According to reports from Chinese media, transitioning from aluminum to magnesium alloys could reduce a humanoid robot's overall mass by 10%, while cutting power requirements by more than 15%.

Thixomolding emerges as the optimal method for safely mass producing these magnesium components, offering significant advantages over traditional die casting.

Notably, it prevents molten magnesium from exposure to the oxygen in the environment, enhancing safety. Even in the event of an issue, only a few kilograms of semi molten magnesium are present in the barrel, far less than the volumes handled in large die casting furnaces.

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Ningbo Asiaway marked a key milestone in its expansion with the successful production of a component using its new 5,000 ton die casting island at the San Luis Potosí, Mexico, facility. This part, a custom developed clutch housing created in collaboration between Asiaway Mexico and its customer, is slated for mass production starting in Q4 2025.

The company has finished the first phase of its 32 Acres plant in San Luis Potosí, outfitted with die casting machines ranging from 350 to 3,500 tons. The addition of the 5,000 ton unit, from LK Machinery, paves the way for further upgrades, including planned installations of 7,200, 12,000, and even 16,000 ton machines, pending confirmation of orders from the North American market.

This state of the art equipment empowers the plant to manufacture around 4 million small and medium sized die cast parts each year, supported by an integrated production chain that spans aluminum smelting, die casting, machining, post-processing, and surface treatment.

On July 30, 2025, Nemak announced a definitive agreement to acquire the automotive business of GF Casting Solutions, a Switzerland based leader in lightweight casting components. The deal, valued at an enterprise value of approximately $336 million, is expected to close in the second half of 2025.

As a division of the Swiss industrial company Georg Fischer, GF Casting Solutions' automotive business is headquartered in Switzerland and generated approximately $707 million in annual revenue in 2024.

The transaction encompasses the full automotive operations, including an R&D center in Switzerland and nine production facilities across the world. It involves around 2,500 employees and a product portfolio where about 80% targets e-mobility, structural, and chassis applications.

Excluded from the deal are GF's iron foundry in Leipzig, Germany, as well as its aerospace and industrial gas turbine operations in Novazzano and Stabio, Switzerland, and Arad, Romania.

GF Casting Solutions operates two Gigacasting focused production facilities in China and Europe, with a third under construction in the United States.

Nemak has been quietly advancing its Gigacasting capabilities, and this acquisition unites two of the largest non Chinese suppliers investing in the technology.

I've contacted GF to explore how this deal will shape their Gigacasting initiatives, and I’m optimistic we’ll have more information coming in the next few weeks for the readers of The Gigacasting Newsletter.

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