For decades, process stability in semi-solid casting has been the single biggest barrier to scaling the technology. With automotive quality departments demanding verifiable, traceable, and reproducible solid-fraction data, the days of “trust us, we’ve done 5,000 quenches” are over. In this sponsored episode, Fabian Niklas interviews Staffan Zetterström, not as co-host, but as Marketing & Sales Manager of Comptech Rheocasting, to reveal a quiet revolution. A new solid-fraction analysis software developed jointly with academia and powered by machine learning. It’s a candid look at why an equipment manufacturer took the leap into software, what it actually solves for foundries, and what this signals for the future of process control, gigacastings, and data-driven casting development. Key Insights * You cannot scale semi-solid casting without proving your solid fractionAutomotive OEMs are increasingly asking two questions: Is your process stable? And what solid fraction do you have? Without hard data, foundries won’t pass nomination gates, no matter how good their slurry looks on paper. * Machine learning + metallurgy = a breakthrough in usabilityThe software automatically analyzes microstructures using models trained in collaboration with leading researchers at Jönköping University. Customers simply upload a polished sample; Comptech validates the rest. The approach blends advanced algorithms with decades of metallurgical expertise to deliver numbers engineers can trust. * Foundries need digital tools because casting leaves zero margin for errorProducing a rear floor, battery tray, or front cradle every 60 seconds means any alloy mis-specification or solid-fraction drift multiplies into catastrophic cost and unmanageable recalls.Software-based validation is quickly becoming a necessity, not a luxury, for gigacasting programs. The amount of data required for optimization simply cannot be handled manually. * Building software as a hardware company is messy, but necessaryComptech openly shares how challenging it was for a traditional hardware-focused organization to create software. Translating academic research into a tool that can be used at 3:15 in the morning on the shop floor required a complete shift in mindset. The team had to rethink manuals, user flows, pricing, packaging, and even internal processes such as accounting and distribution. “Would we do it again? Absolutely!” Despite the cost, uncertainty, and growing pains, Comptech says developing this software was essential. It solves a foundational problem, enables more machine sales, unlocks validation for customers, and prepares the industry for the next era of data-driven casting development. Software is no longer optional — it’s the next strategic layer of competitiveness. Whether you’re an equipment supplier, foundry manager, quality engineer, or casting developer, this episode shows how digital tools are becoming essential to winning nominations, qualifying parts, and securing the next generation of high-value casting programs. Thank you for listening. We’ll see you in the next episode, where we’ll continue to bring you the latest insights and updates from the casting world. Don’t forget to ask questions, write comments, or make suggestions for future episodes. Until next time, keep casting strong! Fabian and Staffan This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit goldcasting.substack.com
