Modularization for reuse of HPDC tools (MoReuse)

Purpose and goal

High Pressure Die Casting (HPDC) of large objects presents challenges, e.g., giant size of machines and tools, varied wear mechanisms on tool surfaces, and need for competence development. The MoReuse project aims to understand and define key tool parameters affecting wear and tool-life, develop systematic measurement methods, and propose solutions to prevent and fix wear. This knowledge will be used to create a strategy for modularizing die casting tools and a model for smart maintenance.

Expected effects and result

MoReuse will deliver methods for modularizing HPDC tools to enable circularity, material solutions for extended tool life, and non-destructive wear assessment for smart maintenance. These innovations support climate-neutral production and align with FFI’s roadmap by enabling reduced greenhouse gas emissions through improved energy efficiency and increased use of secondary aluminium.

Planned approach and implementation

MoReuse brings together Comptech, Jönköping University, RISE, Uddeholm, and Volvo Cars. The project is built around two modules: Design for Circularity (covering material, process, and modularization solutions) and Predictive Maintenance (focusing on wear measurement and modelling). Two industrial PhD students will engage in research and disseminate knowledge within their organizations. The results will enable modular tool design, digital twins, and circular strategies.