Die-casting is radically transforming the world of industrial manufacturing, enabling the production of lightweight, durable, and highly complex components. Thanks to advancements in high-pressure die casting (HPDC), low-pressure die casting (LPDC), and gravity die-casting (GDC), it is now possible to manufacture parts with extremely thin walls, down to 0.75 mm, without compromising structural integrity. This has made die casting a key technology in industries where weight reduction is crucial, such as automotive, aerospace, and consumer electronics.
The global die casting market was valued at approximately $100 billion in 2023 and is projected to grow to $140 billion by 2028. This expansion is driven by increasing demand for more solutions that are efficient, the adoption of advanced materials, and the integration of digitalization and data collection. Today, intelligent die casting systems enable real-time monitoring, predictive maintenance, and optimized process control, ensuring higher productivity and quality. The use of advanced sensors and artificial intelligence allows for real-time data collection and analysis, improving every stage of the production process while minimizing waste.
A concrete example of this evolution is Gigacasting, which is revolutionizing automotive manufacturing with machines offering up to 20,000 tons of clamping force. The goal is to reduce the number of components and simplify assembly processes—an increasingly critical necessity with the rise of the electric vehicle (EV) sector, where optimizing production costs has become a major challenge for automakers. Die-casting has reached an unprecedented level of sophistication, driven by technological innovation, digitalization, and new production requirements. With the adoption of advanced data collection systems and smart manufacturing technologies, the industry is improving in terms of efficiency, quality, and sustainability. The sector is set to expand further in the coming years, potentially redefining the way industrial components are designed and produced.
In the die casting process, thermal control of the mold is a key factor in ensuring both quality and mold longevity. Before production begins, each mold must be heated to the optimal temperature to prevent structural issues and defects in the cast parts. A significant temperature difference between the mold and the molten metal can create surface stresses, accelerating mold wear and compromising product quality. Conversely, maintaining uniform temperature distribution and reducing thermal peaks helps prevent premature damage, such as cracks or porosity, thereby extending the mold's lifespan. Poor temperature control often leads to a high scrap rate, negatively affecting production efficiency and plant lifespan. To achieve parts with a good surface finish, dimensional accuracy, and optimal mold filling, it is crucial to carefully manage the mold’s thermal balance while also improving cycle times and production yield.
The third generation of Marposs’ Total Thermal Vision (TTV) represents a significant advancement in die casting thermal control, incorporating major improvements based on extensive industry experience, with over 300 systems installed worldwide. Over the years, the TTV system has proven its value in projects involving high-value-added components, where the return on investment has been evident within the first few months of use. This success is possible thanks to an increasingly reliable thermal camera and advanced software. The latest evolution allows for more precise measurement of mold surface temperature (±2 degrees compared to the previous ±5 degrees), improving product quality and optimizing both thermal regulation and the spraying phase. The system’s adoption undoubtedly helps reduce waste and increase overall equipment effectiveness (OEE), making it particularly useful for modern large-scale presses and the emerging trend of Gigacasting.
At the same time, starting in 2025, Marposs will expand the TTV product line with more modular solution adaptable to presses of any size by varying the number of thermal cameras and the level of integration. In this context, the company is developing the TTV Light, a simplified and cost-effective version designed for medium-to-small presses, featuring reduced dimensions, an optimized mechanical design, and high-performance quality at an affordable price.
Beyond mechanical innovations, digitalization is becoming a fundamental pillar for improving production. Integration with the Manufacturing Execution System (MES) and the Internet of Things (IoT) enables real-time process monitoring, ensuring more efficient overall management. The TTV system supports this transformation by collecting thermal data, which can be used for in-process and post-process analysis. Additionally, the use of artificial intelligence in combination with TTV could help reduce scrap rates and improve productivity while decreasing reliance on operator expertise.
Thanks to these innovations, Marposs remains a benchmark in the development of thermal control solutions for the die casting industry, anticipating market demands related to digitalization and AI adoption. We aims to provide cutting-edge solutions to make the foundry environment as efficient, sustainable, and future-ready as possible.