Powering the Next Generation of Vehicle Production
Rigid Glasweve (RGW) filters, a patented, best-in-class filtration technology that is helping low-pressure die casters produce cleaner, more consistent aluminum castings for subframes and other critical vehicle components.
As modern vehicles face increasing performance targets, automakers continue to push for lighter components that improve fuel efficiency all while still meeting uncompromising performance and safety standards. This in turn raises the bar for casting quality. Traditional filtration solutions often struggle to meet the elevated demands. That’s why Pyrotek has worked closely with automotive manufacturers to develop Rigid Glasweve (RGW) filters, a patented, best-in-class filtration technology that is helping low-pressure die casters produce cleaner, more consistent aluminium castings for subframes, wheels, suspension parts, and other critical vehicle components.
Among the manufacturers advancing these next generation casting processes is BMW Group’s plant in Landshut, Germany. The facility incorporates a range of advanced consumable technologies from Pyrotek as part of its highly engineered aluminium casting operations.
A standout innovation for automotive producers is Pyrotek’s Rigid Glasweve® (RGW) filter technology. RGW has become a best-in-class solution for low-pressure die casters manufacturing structural components such as vehicle subframes and other critical aluminium parts.
RGW filters deliver several performance advantages:
- Internal recycle, melting sprues internally which saves money on tolling, and helps casters meet recycling KPIs and reduces overall environmental impacts of their production processes.
- Extremely low burn-off in oxygen-deprived casting environments, reducing gas inclusions and improving metal quality.
- High rigidity and dimensional stability, maintaining filter integrity throughout the casting cycle.
- Cleaner alloy streams, thanks to the elimination of iron introduction associated with steel mesh filters.
- Streamlined production, by eliminating the need to saw off metal filter remnants, casters can simplify downstream processes and reduce waste.
Automakers know they need to push the limits of aluminium casting as they continue the ongoing pursuit of high-strength casting performance and ultra-low-weight car builds. The characteristics of RGW (highlighted above) help casters achieve the high-strength, low-weight, and consistent quality goals that are demanded all while maximizing internal recycle streams.
Less iron in process flows and, ultimately, aluminium alloys are key to automakers' pursuits. Wire mesh filters introduce too much iron for modern processes and vehicles. Iron levels must go down to ensure part fatigue strength and weight reduction targets are met. Recyclability also improves along with the elimination of processes like sawing.
BMW in Landshut developed and has advanced metal quality and casting processes with the highest specifications, incorporating technology like RGW filters. Others are following suit and they count on such transparency and performance documentation to make the switch from metal filters. That is how current users gained total confidence and how, to date, more than 100 million RGW filters have been supplied, used, and recycled over the past eight years.
Pyrotek Rigid Glasweve installs in the sprue bushing or at the top of the stack‑up and works with a wide range of low‑pressure die‑casting systems and for a wide range of parts, including wheels, suspension parts and subframes.
“Pyrotek is always partnering with technical leaders in the automotive manufacturing industry on new product developments,” says Andrew Carlson, Pyrotek Global Product Manager for RGW and other Foundry Products. “We have a huge appreciation for the casting and foundry teams we work with around the world, whose professional analysis and support has been invaluable.”
Pyrotek places strong emphasis on ensuring that its consumables integrate seamlessly into customer workflows. The company is expanding its advanced product-quality reporting and environmental documentation to support customers’ evolving requirements and sustainability goals.
With RGW filters, Pyrotek is helping casting plants worldwide achieve cleaner alloys, more efficient processes, and higher performance aluminium components, supporting the next generation of automotive innovation.
Contact Andrew Carlson, Pyrotek Global Product Manager for RGW and other Foundry Products, to learn more.
Posted in Case Study, Product Spotlight, General News, Feature, Article, New Product.
Tags: Aluminium, Filtration, Foundry, Manufacturing, Recycling, Sustainability, Europe.