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Summary of the 21st China Die Casting Congress and Visit to Dongfeng’s Gigacasting Facility + Next Events
The 21st China Die Casting Congress, held from March 25–27, 2026, at the Crowne Plaza Wuhan Development Zone, brought together the global die-casting community for three days of technical exchanges and collaboration opportunitiens.
Under the theme “Al & Mg, Casting a Lighter Future”, the congress positioned lightweighting not as a competitive advantage but as a strategic imperative for the entire industry, particularly in new energy vehicles (NEVs), aerospace, and 3C electronics.
Aluminum solidified its role as the go-to material for large-scale structural integration and Gigacasting, while magnesium emerged as the next frontier for even greater weight reduction, despite ongoing challenges in process stability, corrosion protection, and global supply-chain maturity.
The program was packed with high-value content:
March 25: A dedicated Magnesium Alloys Application Challenges and Industrialization Seminar, and an offline trial training session for die-casting technicians.
March 26: Opening ceremony, plenary keynotes, parallel technical forums on mega-casting, magnesium die casting, low-pressure/squeeze/semi-solid processes, plus a casting display and gala dinner.
March 27: Final technical sessions and the factory visit to Dongfeng.
Some of my personal highlights from the event (among the speeches I attended);
Stainless magnesium technology: R&D innovation from Alloy materials to Thixomolding processes - Zeng Xiaoqin, Vice President and Professor, Shanghai Jiao Tong University
Gigacasting technology - practice, insights and future - Wan Li, Deputy General Manager, Guangdong Hongtu Technology
Challenges for automotive HPDC components made from aluminum - Anders E. W. Jarfors, Professor, Jönköping University, Sweden
AI-Driven Quality control in Mega-Casting - Liu Libing, Smart Manufacturing Engineer, Xiaomi Automobile
Next-Generation Cast Components Enabled by Physics-AI Driven Technologies - Sajjad Amirkhanlou, Founder & CEO, MetalNx
Visit to Dongfeng Gigacasting Plant in Wuhan
The congress culminated in a much-anticipated Premier Factory Visit to Dongfeng. Delegates visited the world’s largest 16,000 ton and 10,000 ton integrated die-casting production lines, supplied by LK Machinery, housed in a dedicated ~47,000 m² facility focused on ultra-large structural components for NEVs. More information here.
The visit offered participants a rare, up-close look at the scale of the world’s largest die casting machine. It was a little disappointing that we couldn’t take pictures nor had time to ask questions, but I understand they are in a race against time to complete and extremely hard and ambitious project.
It was definetely an exciting and unforgettable experience and I hope I will be able to bring you a more detailed report about the plant on the next edition of The Gigacasting Newsletter.
A special thanks to the subscribers of The Gigacasting Newsletter which I had the great honor to meet in person for the first time; Professor Anders Jarfors, Sajjad Amirkhanlou, Shigetake Kami, Shin Hirabayashi, Andreas Würzer and Denis Hopp.
I also want to thank; Martin Tauber, Tom, Iris Li, Jost Gaertner, Yu Zhu, Amy and Wolfgang Edmayr, Sining Wang & all the people from the Bühler team.
Finally, I want to give a very special thanks to Tracy Feng and Sunny Song from Soartec Consulting and to Lindsay Bao from Shenyang Zhongzhu Foundry Productivity Promtion Center for making the trip possible and contributing to the development and sustainability of The Gigacasting Newsletter.
20th Shanghai International Diecasting & Nonferrous Exhibition
I will attend the International Diecasting & Nonferrous Exhibition. Held at the Shanghai New International Expo Center (Hall N1–N4) From July 15ᵗʰ to 17ᵗʰ.
Under the theme “Twin Engines: Al & Mg, A Lightweight Future”
This is your biggest chance to learn about Gigacasting and magnesium Thixomolding, meet people and companies, directly where most of the innovation in the die casting industry is taking place.
Book your visit, your booth or a special factory tour here
Is there any company you want to meet privately at the event? Visit diecast-event.com/cid, alternatively you can directly contact;
Ms. Tracy Feng | Tel/WhatsApp: +86 13916927105 | Line: +66 980427102 | Email: [email protected]
Ms. Sunny Song | Tel/WhatsApp: +86 13761250456 | Email: [email protected]
SEA Die Casting 2026
Another event I highly recommend and which I plan to attend in the future, is the South-East Asia Die Casting.
Bangsaen, Chonburi, Thailand – SEA DIECASTING 2026, Southeast Asia’s only dedicated die casting conference and exhibition, will take place from May 20–22, 2026.
Under the theme “Powering Southeast Asia, Forging a New Age”
The event will unite global industry leaders, experts, and key decision-makers to shape the future of die casting in the region.
Southeast Asia has emerged as a key hotspot for international manufacturing investment.
Thailand, in particular, is at the forefront of this transformation, with its rapidly growing electric vehicle and electronics sectors driving strong demand for advanced die casting solutions and integrated supply chains.
Is there any company you want to meet privately at the event? Visit diecast-event.com/cid, alternatively you can directly contact;
Ms. Tracy Feng | Tel/WhatsApp: +86 13916927105 | Line: +66 980427102 | Email: [email protected]
Ms. Sunny Song | Tel/WhatsApp: +86 13761250456 | Email: [email protected]
Do you plan on visiting any of these events? If you do write to [email protected] or any of my social media channels and let me know!
Duoli Strengthens Partnership with Bühler With A New Order
At the 2026 Die Casting Conference, Bühler Group, a global leader in die casting technology, officially announced that Duoli Technology has signed a major new order.
Duoli, one of the major Chinese Gigacasting producers will expand once again its Gigacasting portfolio with even more Bühler Carat machines.
Multiple large die casting islands, including the Carat 920 and Carat 720 models (9,200 ton and 7,200 ton) will reinforce Duoli’s Gigacasting production capacity. Duoli’s data is tracked in The Gigacasting Database.
This latest investment reflects Doli Technology’s strong endorsement of Bühler’s die casting technology. The company had already deployed and successfully put into operation Bühler series equipment at four of its production bases in China.
In full-scale mass production, the machines consistently achieved excellent yield rates, demonstrated outstanding operational stability, and maintained an extremely low failure rate results that directly supported this repeat purchase according to the joint Duoli-Bühler announcement.
Carat 920 at Duoli’s facility
Volvo Cars Selling a Brand-New, Unused LK 3,500-ton Die Casting Line from their Gothenburg Facility 🚨
Volvo has committed its Gigacasting strategy to 8,500-ton Bühler machines at Torslanda, now in mass production for the EX60 rear underbody.
This LK Impress Plus DCC 3500 was installed and commissioned at Volvo's Gothenburg facility with a dry test run only. It never entered production. Volvo is now selling the complete die casting island.
-> Machine: LK Impress Plus DCC 3500, two-platen, 35,000 kN
-> Condition: Unused, 2022 build
-> Melting: Støtek two-chamber gas-fired furnace, holding furnace, dosing furnace
-> Automation: ABB robots, Fondarex vacuum, Keyence laser marking, trim press
-> Spare parts included
This is brand-new structural die casting capacity with zero lead time, in a market where Western foundries wait over a year for new machine deliveries.
Ford’s ‘Unicasting’ Tech Promises Lower Repair Bills
Ford is making what CEO Jim Farley calls the most radical change in vehicle construction since the Model T. Starting with a new $30,000 midsize electric pickup next year, the automaker will introduce Gigacastings or as Ford calls them “unicastings”. One in the front and one in the rear.
Early concerns that large castings would drive up crash repair bills appear unfounded. Ford says repairability was a core design priority from day one. “We quickly found that it’s actually easier to repair a vehicle that has unicastings,” said Alan Clarke, Ford’s executive director of advanced electric vehicle development.
Independent research backs this up. A Thatcham Research study compared a Tesla Model Y with Gigacastings to a conventionally built Model 3. In crashes requiring partial replacement of the large casting, the Model Y was nearly $3,000 cheaper to repair. Full casting replacements were about $700 less expensive. Many low-speed rear-end collisions caused no damage to the casting at all. Full article here
The key is smart design. Both Ford and Tesla incorporate crash cans that absorb the brunt of common low- and moderate-speed impacts. Damaged sections of the casting can be cut at predefined zones and replaced with modular repair parts that slide in and attach using adhesive, structural rivets, and bolts. No welding required.
Ford’s own testing confirms repairs are cost and time-competitive with traditional methods. Collision repair professionals who already work on Tesla Gigacastings report the process is often simpler than conventional sheet-metal repairs. Industry expert Terry Woychowski of Caresoft Global called fears of skyrocketing repair costs “an unfounded concern.”
Ford plans targeted technician training on casting-specific sectioning and inspection techniques and will use its extensive dealer network to ensure widespread repair capability. The company notes that the new approach may actually require less specialized skill than some current conventional repairs.
While certain complex damage scenarios could still prove costlier, the overall message is clear: when engineered with repairability in mind, large castings can deliver lower repair bills, a welcome development as Ford positions its affordable new electric pickup as part of the solution to the industry’s affordability crisis.
This article was summarized from an original story in Automotive News
Ford introduces Unicasting: https://www.industryarsenal.com/p/weekly-gigacasting-news-50
Bojun Technology Expands Partnership With LK Machinery
Jiangsu Bojun Industrial Technology has signed a cooperation agreement with LK Group on April 2, 2026, in Kunshan, Jiangsu. The deal accelerates Bojun’s expansion into Gigacastings and the fast-growing magnesium alloy semi-solid sector by introducing a new batch of ultra-large die-casting units and Thixomolding equipment.
Bojun is acquiring multiple high-tonnage die casting machines of 10,000 ton, 9,000 ton, 7,200 ton, 5,000 ton as well as smaller 3,000 ton and 800 ton machines.
Part of the deal includes LK’s TPI magnesium Thixoforming technology, targeting complex, large, thick-walled structural parts for new energy vehicles, electric two-wheelers, and robots.
Changhan’s Subsidiary Nears Mass Production With 5,000T Magnesium Thixomolding Machine
Chenzhi Lightweight Technology, a wholly-owned subsidiary of Changan Automobile, has successfully commissioned its 5,000 ton die casting unit along with its magnesium Thixomolding module.
The machines is equipped with a magnesium Thixomolding module made by TPI and capable of an 18kg shot weight. Trial production of large magnesium structural parts, including body components, tailgate inner panels, and electric-drive housings began at the end of March. The line is now in final countdown to full commercial operation.
