The Spanish die casting industry has developed into a major player on the European market. So it is no wonder that it was strongly represented at the last EUROGUSS. With a focus on technological innovations such as gigacasting and sustainable production methods, it is contributing to the further development of the automotive industry. At the same time, issues such as rising energy costs and a shortage of skilled workers are also at the center of challenges in Spain
Growth through innovation: Spain's die casting industry in transition
The Spanish die casting industry has become an important player in Europe in recent years. With a particular focus on aluminum die casting, the country has firmly established itself in global supply chains. This development is largely driven by the automotive industry, which relies heavily on lightweight yet robust components. Electric vehicles in particular benefit from the advantages of aluminum die casting, as weight savings play a key role here.
With growth of 54.4% in the metal forming sector in 2023 compared to the previous year, Spain is experiencing dynamic development, which is also driving the die casting industry forward. Innovative technologies such as gigacasting are increasingly seen as the key to further expansion.
According to Fundigex, the export association of Spanish foundries, around 121,000 tons are produced in the non-ferrous casting industry in Spain, making this sector a significant part of the Spanish foundry industry. Around 41 percent of all foundries in Spain specialize in non-ferrous casting, and 31 percent of the foundry industry's workforce is employed in this sector. In addition, 12 percent of exports and 33 percent of the foundry industry's total turnover are accounted for by this sector, underlining its role within the national economy.
Sustainability as a driver for change
With the growing importance of sustainability in the industry, the die casting sector has also realigned itself. In Spain, as throughout Europe, there is an increasing focus on environmentally friendly production processes that reduce both energy consumption and emissions. Aluminum in particular, which is both recyclable and lightweight, plays a key role in this context. Spanish companies are increasingly focusing on recycled materials and energy-efficient processes in order to meet the requirements of the European Green Deal.
In addition to the introduction of environmentally friendly materials, the Spanish die casting industry has also invested heavily in the digitalization of its production processes. Technologies such as artificial intelligence (AI) and automation are enabling companies to make their production lines more efficient and further optimize resource consumption. Examples of this include robotic solutions that are used in the casting process to monitor and control workflows.
Gigacasting: The revolution in vehicle construction
Gigacasting is currently the dominant theme in the die casting industry, and Spain is no exception. The European automotive gigacasting market was estimated at USD 1.5 million in 2023 and is expected to grow at a compound annual growth rate of 72.76 percent. This would mean that it would be worth 344.4 million US dollars in 2033. The advantages are obvious: fewer components mean fewer assembly steps, lower error margins and a higher production speed. Die casting is therefore making an important contribution to the further development of the automotive industry, which is increasingly focusing on electromobility and sustainability.
The positive development of the Spanish industry is also reflected in the turnover figures, which reached a new high of 2,157.3 million euros in the advanced manufacturing and machine tool technologies sector in 2023. This progress is also reflected in the die casting sector, which is benefiting from investment and innovation in metal processing.
Spain is the fourth-largest manufacturer of aluminum die castings in Europe and is showing great dynamism in the introduction of innovative technologies. A key driver is the automotive industry, which is also strongly developed there. Spanish companies are well represented at EUROGUSS – companies such as Industrias Lebario S.L., Fagor Ederlan S.Coop., Metalflow S.A., Draxton and Hormesa S.A. can be found there.
Challenges for the SME sector
Despite its successes and progress, the Spanish die casting industry is also facing challenges. Rising energy costs, which are a particular problem in Europe, are weighing on the industry's competitiveness. For small and medium-sized companies in particular, which form the backbone of Spanish foundries, these costs pose a serious threat. In order to maintain their competitiveness, many companies are calling for government support and a reduction in bureaucratic hurdles.
Another key point that was also discussed at EUROGUSS 2024 was the recruitment of young talent. Spanish foundries, like many others in Europe, are facing a shortage of skilled workers. To counteract this, many companies are cooperating with universities and research institutes. The aim is to inspire young talent for the industry and present die casting as a modern and future-oriented industry.
The future of Spanish die casting
The Spanish die casting industry has made considerable progress in recent years. Thanks to the increased use of gigacasting and other innovative technologies, the country has become an important player on the European market. Sustainability plays a central role here: Spanish foundries are increasingly focusing on environmentally friendly materials and energy-efficient production processes in order to achieve the EU's climate targets.
Like the mechanical engineering sector, Spain's die casting industry was able to benefit from a record 21.8 percent increase in exports. The high demand from countries such as the USA and Mexico demonstrates the international competitiveness and success of Spanish companies.
At the same time, the industry is facing major challenges. Rising energy costs and the shortage of skilled workers could affect the competitiveness of Spanish foundries in the future. In order to meet these challenges, it is crucial that the industry continues to focus on innovation and digitalization. Only in this way can Spain maintain its position as the leading die casting location in Europe and remain competitive in the future.
