More than just a change of material
Switching from steel to aluminium is far from a one-to-one replacement. Aluminium has completely different mechanical properties, meaning each part must be carefully re-engineered. RG Castings Group’s engineering team conducted a thorough analysis of all 15 components, mapping out their functional requirements, dimensions and load conditions. Based on this, the right alloying elements were selected to achieve the required strength, without adding unnecessary weight.
Next, the entire casting process was simulated using advanced 3D technology. These simulations enabled the team to optimise the design, identify potential issues early on, and avoid unnecessary prototyping costs, significantly improving development efficiency.
From prototype to serial production
Once the final designs were approved by the client, RG Castings Group began the prototyping phase. The first test castings were produced using the permanent mould (coquille) casting technique, then rigorously evaluated for mechanical strength, dimensional accuracy and durability.
Following successful validation, full-scale production was launched. Today, several thousand parts per component leave our foundry each year.
Lighter, more efficient and sustainable
In addition to the technical advantages, switching to aluminium castings contributes to a more sustainable and energy-efficient solution:
- Aluminium is lighter, reducing the overall weight of the trailer and thus fuel consumption.
- Aluminium is corrosion-resistant, resulting in longer lifespan and lower maintenance.
- Aluminium melts at lower temperatures than steel and is 100% recyclable, significantly lowering the environmental impact of the production process.
Through this collaboration, RG Castings Group and the client not only enhanced the functionality of their trailers, but also took a step forward in enabling more efficient and sustainable transport.