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Rheocasting

Rheocasting components bring lightness to vehicle construction

SAG is the technology leader in rheocasting – a special casting process in which aluminium is cast in a semi-solid or semi-liquid state. This so-called semi-solid process has many advantages.

Proven Technology. Unmatched Performance.

The future of Aluminium Casting starts here

At SAG, we don’t just innovate, we bring innovation into the real world. With over 30 years of experience in metal processing, our proprietary Rheocasting technology delivers a game-changing solution for manufacturing lightweight, high-strength aluminium components.

More than just a casting method, rheocasting combines the best attributes of forging, high-pressure die casting, low-pressure die casting, and investment casting, offering OEMs and Tier 1 suppliers a proven, scalable, and sustainable alternative to conventional methods.

Why rheocasting?

Our process is engineered for performance, precision, and production efficiency, ideal for next-generation mobility platforms and structural components.

Forging-Level Strength & Ductility
Helium-Tight Weldability & Smooth Surface Finish
High-Speed Production Cycles (HPDC Efficiency)
Complex, Near-Net Shape Design Capabilities

With rheocasting, you get all these benefits in one process refined, patented, and already running at full scale in the automotive sector.

Functional Integration. Smarter Production.

Fewer individual parts Reduced manufacturing steps Shorter production time and supply chain Lower tooling, inventory and labor costs Fewer individual parts Reduced manufacturing steps Shorter production time and supply chain Lower tooling, inventory and labor costs Fewer individual parts Reduced manufacturing steps Shorter production time and supply chain Lower tooling, inventory and labor costs

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When every gram counts, Rheocasting delivers:

The result? Better handling, enhanced energy efficiency, and reduced emissions, all while cutting production costs.

Up to 60 % less weight

compared to steel parts of the same size. Areas of application: Vehicle components, chassis parts, crash-relevant parts.

Cost-effective because of near net-shape

No milling, deburring, grinding necessary. Areas of application: Visible components, interior parts, brakes.

Best thermal and electrical conductivity

20 % higher thermal conductivity, improved EMC properties, best for applications in telecommunications and battery technology/power electronics

Best weldability and pressure density (helium density)

Areas of application: Vehicle components, chassis parts, pressure vessels, radiators, pumps.

Optimum mechanical strength and elongation

Figher fatigue strength than steel. Areas of application: Vehicle components, chassis parts, crash-relevant parts.

Allows wall thickness transitions and freedom of design

Any design possible, even for components with different wall thicknesses, e.g. in the field of bionics. Best functional integration, weight optimization at equal installation space.

Sustainability, Engineered In

Rheocasting doesn’t just reduce weight. It contributes to a greener tomorrow

100% recyclable aluminium

Zero CO₂ emissions

Lighter vehicles

From Idea to Industrialization

With SAG, you get more than a process. You get a development partner.

From first sketch to serial production, we’re with you all the way.

Concept & design consultation
Rapid prototyping and simulation
Tooling & industrial process development

Full automation for high-volume production
Just-in-time delivery and system integration

Rheocasting is a special semi-solid casting process for aluminium.

Up to 60 % weight reduction compared with steel parts and other significant advantages were honored by VOLVO with an innovation award. Innovative technologies for processing light metal alloys have undergone enormous development in recent years. These include rheocasting – a special casting process in which aluminium in a semi-solid state is processed into lightweight components with special material properties.

Where rheocasting makes a difference

Perfect for:

EV & Hybrid platforms
Suspension and chassis parts
Cooling and pressure systems
Battery modules and safety-critical components

We’re not just a supplier, we’re your end-to-end solution provider for lightweight, high-performance aluminium components.

Key benefits at a glance

High mechanical strength & ductility Laminar metal flow = low porosity High thermal conductivity Scalable, automated TRL 9 process Short cycle time for high-volume runs High mechanical strength & ductility Laminar metal flow = low porosity High thermal conductivity Scalable, automated TRL 9 process Short cycle time for high-volume runs High mechanical strength & ductility Laminar metal flow = low porosity High thermal conductivity Scalable, automated TRL 9 process Short cycle time for high-volume runs

Excellent weldability (helium-tight) Near-net shape, no machining needed Functional integration for design freedom Variety of alloys & wall thicknesses Excellent weldability (helium-tight) Near-net shape, no machining needed Functional integration for design freedom Variety of alloys & wall thicknesses Excellent weldability (helium-tight) Near-net shape, no machining needed Functional integration for design freedom Variety of alloys & wall thicknesses