Aluminium injection HPDC

The Group offers its customers different production processes and technologies related to aluminium: from casting and injection to machining and possible assembly of components. We have decades of accumulated experience in development and manufacturing. Together with the technical know-how of our teams, allow us to create a high quality, value-added end product for customers all over the world.

High Pressure Die Casting

High Pressure Die Casting (HPDC) is the process by through which the pre-melted aluminium is injected under high pressure into a mould in the shape of the desired part. This process is carried out at high temperatures, which can reach up to 1,000 ºC, depending on the type of alloy used.

This technology enables the production of aluminium components with high precision and quality thanks to the rapid solidification of the molten metal in the mould. The high pressure ensures that the molten aluminium completely fills the pre-designed container and captures all the desired details, producing parts with high dimensional accuracy and smooth surface finishes.

Once the part is removed from the mould, it undergoes a pressing process, followed by a process that ensures the overall surface finish, such as shot blasting. In this way, the surfaces are prepared before further processing, such as machining. With this last process we achieve the necessary and definitive shapes and tolerances required for the part.

Aluminium die castings are durable and corrosion resistant, making them suitable for a variety of automotive applications. In addition, it is a fast and efficient process for manufacturing large volumes of components.

Teknia's comprehensive capabilities in aluminium injection

As a supplier of multi-technology solutions, Teknia seeks to offer its customers high added value in all products, as well as maximum quality and reliability. Based on this maxim, the company integrates the design, simulation and construction capabilities of the moulds required for the casting process.

In addition, the Group’s plants that work with this technology specialise in high-pressure aluminium injection and CNC machining. They offer a high degree of automation and robotisation of all casting and CNC machining processes, as well as component assembly capabilities and ancillary product processes.

A very important phase before series production is the industrialisation of the products in cooperation with the customers’ engineering services. This process, before casting and machining tools are produced, avoids many potential problems in manufacturing. For example, porosity, a critical issue in high-pressure aluminium die casting technology.

Close relationships with customers enable us to ensure that casting and machining processes are designed from the outset in an effective, efficient and optimised manner, making HPDC a true ‘State of the Art’. This ability to take aluminium die casting to its highest level means that Teknia is able to cast, press and shot blast in automated cells.

The process continues on CNC machining lines with washing, DMC, assembly and leak testing processes integrated through a high degree of automation. As a result, these production lines enable a consistent quality chain to be maintained, minimising errors and increasing responsiveness to customer demands.

Wide range of products for the automotive industry

High-pressure aluminium injection is a technology that enables the manufacture of lighter and stronger aluminium parts. As such, it is a widely used production method in the automotive sector, where weight and safety are essential factors.

Key products manufactured by Teknia in high-pressure aluminium injection technology include components for the following areas:

Gear steering, such as servohousings, gearbox covers, MCU Housings, Sensor Covers and steering columns. The latter include Body Jackets/Box Rockers and Column Steering Brackets.
New mobility and power electronics, such as inverter housings and covers, BRM housings and Carrier Plates for e-motors/e-transmissions, among others.
Combustion engines and their systems, such as engine brackets or starter motor housings.

Sensor cover

Servohousing

Ventil housing

Gearbox cover

Columna dirección/Bracket

Inverter cover

Inverter housing

BRM housing

A key technology for electrification

The greatest advantages of high-pressure aluminium injection are in the development of electric vehicles. In these vehicles, the lightness of the assembly is crucial for improving energy efficiency and increasing battery autonomy.

In addition, it should be noted that aluminium has excellent thermal conductivity. This valuable property of the raw material helps to manage the heat generated by electrical and electronic systems, ensuring optimal performance and increased durability.

Ultimately, this technology enables the manufacture of complex components with a high degree of precision in the field of electrification. This is the case for inverter housings and covers, electric motor housings and carrier plates for electric vehicle motors and transmissions, among others.

All these elements are essential for the operation and efficiency of electric vehicles, as they protect and optimise the electrical systems.

Teknia plants specialised in aluminium injection

The aluminium injection process represents Teknia’s commitment to sustainability and innovative vision, but also its international capacity to offer high quality solutions using this technology. The Group has aluminium injection solutions in plants in Ampuero (Spain), Tepejí del Río (Mexico), Oradea (Romania) and Vimmerby (Sweden).

Each Teknia high-pressure aluminium injection plant is equipped with ‘State of the Art’ technology. The combination of advanced automation, robotisation and meticulous quality controls enables the manufacture of a wide range of critical components for the automotive industry, ensuring the highest standards of precision and durability.

This approach not only optimises production, but also minimises defects and improves the company’s operational efficiency. Undoubtedly, each of these production plants plays a crucial role in supplying specialised products to local and global markets.

Magnesium injection, a further step in our leadership

The Teknia Vimmerby plant, located in Sweden, adds advanced capabilities for magnesium injection. A process that allows the company to take advantage of the benefits of this raw material and diversify its technological offer, complementing its aluminium injection capabilities.

Magnesium injection is a technique that, like aluminium injection, is used in the automotive industry to manufacture lightweight and durable components. For that reason, diversification is key to meeting the demands of global customers seeking lightweight and efficient material options for new mobility and vehicle electrification.

On a technical level, magnesium has certain advantages over aluminium, especially in the automotive sector. Magnesium is approximately 30% lighter than aluminium, which can lead to further weight reduction in vehicles. As a result, further improvements in energy efficiency and battery range can be achieved.

In addition, magnesium has excellent shock-absorbing properties, making it ideal for components that must withstand high stresses and shocks. For example, the covers of critical vehicle parts such as engine blocks and transmission cases, airbag and steering wheel housings, chassis components or seat structures.

However, it should also be noted that magnesium is more sensitive to corrosion and less resistant to heat compared to aluminium. For this reason, its use in the automotive industry is more limited to certain components that are not exposed to extreme conditions of temperature or humidity.

Sustainability in all processes

High-pressure aluminium injection contributes to the efficiency of automobiles, but also to a large extent to the sustainability of the industry. Aluminium is a recyclable material that can be reused without losing its properties, which is an important aspect in the automotive industry, which is constantly seeking to reduce its environmental impact.

In line with its commitment to sustainability and its innovative vision, Teknia is active in the European battery market and other components production such as converters, inverters and on-board chargers. All these products are manufactured using high-pressure aluminium injection technology.

Sustainability is integrated into Teknia’s business strategy and has been part of the company’s people and operations from the very beginning. For this reason, we are committed to new technologies and the most innovative materials, with the aim of achieving more flexible, efficient and safe processes.

Thanks to the Group’s constant innovation and adaptation to new mobility trends, Teknia has managed to remain at the forefront of aluminium injection technology. The combination of technologies, highly competitive production processes and advanced capabilities for the manufacture of high quality components for the automotive industry ensure that we are well positioned to grow as the electrification market evolves.