Mega-casting in the automotive production system: Expert interview-based impact analysis of large-format aluminium high-pressure die-casting (HPDC) on the vehicle production

Since the revolutionary invention of the conveyor-belt production by Henry Ford in 1913, market player mainly evolved a unique selling point through E-Mobility. Mega-Casting promises a revolutionary simplification of the automotive production system using large-format high-pressure die-cast (HPDC) aluminium structural components in the automotive car body. Through 35 cross-industry expert interviews in the automotive production system, the paper's study has the aim to (1) present first time the analysis of the disrupting Mega-Casting automotive production concept. Based on grounded theory and coding methodology, the economical, ecological, sociological, strategical, and technical potential of Mega-Casting has been assessed to identify its differences and thus the impact on the automotive production system. (2) Expert view on opportunities and challenges of Mega-Casting for each TIER-level in the production system through a detailed Mega-Casting production concept case study.