Goldcasting Podcast

Staffan Zetterström & Fabian Niklas

Learn how to make money in the foundry industry. Listen to the discussions of Staffan Zetterström and Fabian Niklas. Also enjoy the stories of our Guests. goldcasting.substack.com

  1. MAY 14

    GN 71: The Powerhouse BYD and the 15th Five-Year-Plan

    BYD looks like an overnight success story. A company that barely registered as a global car brand a decade ago is now reshaping markets, challenging established OEMs, and forcing the automotive industry to rethink what scale, speed, and vertical integration really mean. Fabian Niklas and Staffan Zetterström look behind the rise of BYD: from batteries and hybrid strategy to government support, supply chain control, pricing pressure, quality concerns, and the broader industrial logic behind China’s long-term planning. The discussion also moves beyond BYD itself when we connect the company’s growth to the next strategic focus areas in China’s Five-Year Plan, including semiconductors, robotics, drones, energy storage, biomedicine, and aerospace. Key Topics * BYD did not happen overnight * The battery became the center of the car * Vertical integration as a strategic weapon * Hybrid strategy and market fit * Government support and industrial policy * The risks behind rapid growth * Chinese competition will not disappear if BYD slows down * The Five-Year Plan points beyond cars “BYD opened the door to make the customers accept buying a Chinese car” Watch or listen to GN 71 to understand why BYD’s rise matters beyond electric cars and what China’s next Five-Year Plan could mean for manufacturing, casting, mobility, and industrial competition. 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. See you in the Podcast, Fabian and Staffan No time for every Goldcasting episode? We launched the Goldcasting Executive Briefing: a paid newsletter with the key strategic takeaways from Goldcasting in a shorter, sharper format. It is built for foundry leaders, suppliers, and industry professionals who want to understand what the latest conversations mean for their business, margins, customers, and future strategy, but lack the time to listen to all the episodes. It is also the best way to support Goldcasting. Subscription price: 29€/month or 290€/year Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

    38 min

  2. APR 30

    GN 70: AI - The Enemy that we Love

    AI is no longer something the foundry industry can laugh off as a distant software trend. Large language models are already being used by engineers, buyers, designers, and decision-makers to explore manufacturing options, compare processes, prepare for meetings, and form first impressions of suppliers. In this episode, Fabian Niklas and Staffan Zetterström look at AI from the perspective of foundry guys, not AI experts. The central concern is not that LLMs (Large Language Models) exist. The real problem is that LLMs often provide poor or outdated answers about casting because the foundry industry has not produced enough accessible, up-to-date, publicly available information for these systems to learn from. That has direct commercial consequences. If an engineer, product designer, or purchasing team asks an LLM whether a part should be cast, the answer may be shaped by outdated textbook assumptions rather than by modern high-pressure die-casting practices. In the worst case, AI does not just misunderstand casting, it quietly sends potential customers somewhere else. The episode is a grounded conversation about what AI can do, where it fails, and why foundries should start testing it from the perspective of their target customers. Key Topics * Why AI drives customers away from casting When an engineer asks an LLM for manufacturing advice, the answer depends on the information available online. If current casting knowledge and marketing material are missing, the model may recommend against casting based on outdated assumptions. * The foundry industry has a visibility problem AI often fails to distinguish between older textbook descriptions and modern die-casting processes. The issue is not only technical accuracy but also the lack of publicly searchable material showing what today’s foundries can actually do. * Try AI Seach from your customer’s perspectiveAsk the same questions your target customers would ask. Search for your process, your applications, your company, and your alternatives and then see whether AI leads people toward your capabilities or away from them. * AI is useful, but only with the right inputLLMs depend heavily on the quality of the question, the available data, and the user’s ability to judge the answer. It can produce convincing text even when the technical conclusion is weak or incomplete. * Marketing cannot be fully outsourced to AI AI can help organize, draft, and accelerate communication, but it cannot replace a company’s identity, technical judgment, or real application knowledge. If a foundry uses AI to create marketing without understanding marketing or without the LLM understanding the foundry industry, the result can be polished but wrong. * Use AI as a servant, not a decision maker LLMs work best for narrow, practical tasks such as compiling information, sorting notes, drafting first versions, or preparing summaries. It should support human expertise, not replace the expert who understands the process, the customer, and the risk. * Be careful with confidential data Never put NDA-protected drawings, specifications, or internal notes into public AI systems. The more sensitive the information, the more important it becomes to think about data control, private systems, and who can access the output. * Start with real bottlenecks, not grand visionsInstead of trying to automate an entire foundry at once, start where AI can remove low-value manual work. The practical value comes from reducing friction in specific tasks while keeping a human in control. “We can do amazing things, but who cares if no one sees them?” Watch or listen to GN 70 to hear Fabian and Staffan test what AI gets wrong about casting, why that matters for new business development, and how foundries can start using AI by asking the same questions their future customers are already asking. 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. See you in the Podcast, Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

    39 min

  3. APR 16

    GN 69 - Rheocasting explained

    Rheocasting is one of the most discussed, misunderstood, and often misjudged technologies in the die casting industry. Some see it as a miracle process. Others remember failed trials from the past and dismiss it completely. In reality, the truth is far more interesting. Rheocasting is neither golden paint nor science fiction. It is a highly capable extension of high-pressure die-casting that opens the door to new alloys, new applications, and new business, but only if it is understood and applied correctly. In this episode, hosts Fabian Niklas and Staffan Zetterström take on the questions they have been hearing for years from foundries, designers, buyers, and engineers. What exactly is Rheocasting? Why did so many early attempts fail? What is solid fraction? Why does flow behaviour change so dramatically? And what does it actually mean in terms of tool life, machine size, leak tightness, and structural performance? What starts as a technical explanation quickly becomes a broader discussion about process discipline, alloy strategy, production stability, and total cost of ownership. If you have ever seen Rheocasting as a niche process or an unstable curiosity, this conversation will give you a very different picture. Key Topics * What Rheocasting actually is, and what it is not A clear explanation of Rheocasting as an addition to high pressure die casting, not a replacement for it, and why it should be seen as a tool to expand the application range of HPDC. * Why did the previous trial castings fail? Why the process does not fix poor die casting fundamentals, and why metal hygiene, vacuum, tooling, and thermal management must already be under control before Rheocasting can deliver results. * Semi-solid slurry, thixotropy, and the importance of solid fraction An accessible explanation of how slurry behaves, why it may look solid but flow like a liquid under shear, and why the magic only starts once you reach the right solid fraction. * Why older Rheocasting systems struggled A practical look at why so many historical approaches failed in production, and why temperature-controlled systems are not enough when alloy chemistry and liquidus temperature keep shifting in real foundry life. * Why does enthalpy-controlled slurry making change the game? How the RheoMetal approach creates a much more stable slurry condition, and why that stability is one of the key reasons Rheocasting can work reliably in serial production today. * Why alloy selection becomes much more interesting How Rheocasting opens a much wider alloy window than conventional HPDC, including lower-silicon alloys, stronger heat-treatable alloys, recycled alloys, and materials designed for thermal conductivity or sustainability. * Leak tightness, structural performance, and new applications Why Rheocasting is attractive for demanding parts such as structural castings and high-pressure leak-tight components, where conventional die casting often reaches its limits. * Why machine size can go down while part capability goes up How reduced projected area, less gating mass, and lower knocking effects can significantly reduce required locking force and machine size. * Tool life, OEE, and the economics behind the process Why the business case for Rheocasting is not only about part quality, but also about lower tool wear, better stability, and real savings in total cost of ownership. * What Rheocasting could mean for gigacastings Why the discussion is shifting from “can it be done?” to “what does it do for OEE, tool lifetime, and large-scale economics?” especially in very large structural applications. “Rheocasting is not Golden Paint” Rheocasting is not a shortcut around good die-casting practices. It does not reward sloppy fundamentals. But when the basics are in place, it becomes a serious industrial tool that can solve problems conventional HPDC cannot solve so easily. That is what makes this episode so valuable. It does not present Rheocasting as hype. It presents it as what it really is, as a process extension with very real technical and commercial advantages, provided you understand the rules of the game. 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. See you in the Podcast, Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

    45 min

  4. APR 2

    GN 68 - Diversity replaces Cycle Time as a Success Factor

    The foundry industry is not just fighting cycle time, cost pressure, and shrinking automotive volumes anymore. It also struggles to build effective teams that can actually lead transformation out of the crisis. In this episode, sponsored by the Euroguss, hosts Fabian Niklas and Staffan Zetterström speak with Tiziana Tronci and Isabel Jeschek about why diversity, fresh perspectives, and courageous leadership may become far more important than the industry has been willing to admit. What starts as a conversation about equality quickly becomes something much more fundamental. This Gold Nugget explores why mixed teams outperform closed circles, and why change management is no longer optional if the industry wants to stay relevant. From family-business succession to software developers in stubborn old organizations, from trust and boldness to data and leadership culture, this episode shows that the future of die casting will not be decided by machines alone. If you still think diversity is a side topic, this conversation will likely challenge that assumption. Key Topics * Why diversity is becoming a real success factor in die casting A discussion about why foundries can no longer rely on homogeneous teams and old routines if they want to manage today’s transformation. * How mixed teams improve decision-making Why age, gender, background, and professional perspective all matter when companies are forced to rethink markets, business models, and customer needs. * Why is the biggest barrier still mindset The real challenge is not technology or economics, but the cultural mentality inside the foundry industry itself. * What leadership must look like during transformation The role of the leader is not just to decide, but to listen, moderate, give trust, create space, and allow new ideas to develop. * Why courage matters more than routine A conversation about boldness, responsibility, and why managers must dare to bring in people who do not look, think, or work like the old organization. * What happens when outsiders enter a traditional industry Both guests reflect on how coming from different sectors can be difficult at first, but ultimately becomes a source of freshness, new thinking, and strategic value. * Why change management has to come from the top Transformation cannot simply be dropped into an old structure. It has to be moderated, supported, and actively led by management. * Why data matters, but not without people Facts and market analysis are essential, but only become useful when combined with experience, interpretation, and real dialogue across teams. * What the Euroguss Women in Die Casting initiative revealed The first conference panel showed strong interest across the industry and made clear that this topic is no longer niche, but increasingly strategic. “I don’t hire smart people and tell them what to do. I hire smart people, and they tell me what to do.” This episode is not really about equality as a checkbox topic. It is about performance. The die casting industry is under pressure from declining utilization, shifting customer demands, emerging technologies, and a market that no longer rewards passive routines. In that environment, companies need new competencies, new perspectives, and leaders who are brave enough to let those perspectives challenge the status quo. If the industry wants a future, it has to do more than buy new machines. It has to build new teams, new leadership habits, and new ways of thinking. Because the real question is no longer whether change is needed. It is whether the people leading the change are ready to let others in. 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. See you in the Podcast, Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

    1 hr

  5. MAR 19

    GN 67 - How CBAM puts a Price on Sustainability

    The Carbon Border Adjustment Mechanism is no longer a future topic. It has already been impacting global supply chains, pricing structures, and competitive dynamics in the casting industry since January 2026. In this episode, hosts Fabian Niklas and Staffan Zetterström sit down with Marcel Duits, CBAM expert, entrepreneur, and president of the International Association for CBAM, to break down what the mechanism actually means in practice. From emission calculations to supply chain risks, from pricing pressure to strategic opportunities, this Gold Nugget explores one of the most disruptive regulatory changes the industry has faced in decades. What starts as a technical explanation quickly turns into a broader discussion about competitiveness, margins, and how prepared (or unprepared) the industry really is. If you think CBAM is just another reporting exercise, this conversation will change your perspective. Key Topics * What CBAM actually is and why it exists A clear explanation of the Carbon Border Adjustment Mechanism and how it creates a level playing field between EU producers and global imports. * Why CBAM becomes financially real in 2027 The shift from reporting emissions to actually paying for them, and why many companies underestimate the financial impact. * The massive cost difference between default and actual data How missing verified emission data can multiply costs and quickly destroy already thin margins. * Why most companies are still unprepared From lack of awareness to internal complexity, many organizations are only starting to understand CBAM when it’s already becoming urgent. * The hidden complexity of emission calculations Why CBAM is not just a sustainability topic, but also involves customs, finance, procurement, and legal departments. * How CBAM is already reshaping global supply chains Shifts toward new sourcing regions, relocation strategies, and the growing importance of low-carbon production. * Why European producers may gain a competitive advantage How decarbonized production inside the EU can become a strategic benefit rather than a cost burden. * Why sustainability is no longer optional but financial How CBAM directly links emissions to cost, turning sustainability into a hard business metric. “What CBAM-Surcharge are you going to charge?” CBAM is often treated as a compliance topic. Something for sustainability teams or reporting departments to handle. But as this conversation makes clear, the real impact is happening elsewhere: in pricing, margins, and negotiations with customers. Companies importing aluminium, steel, or cast components may soon face significant cost increases depending on their emission data and sourcing strategy. The difference between being prepared and unprepared is not theoretical. It is expensive! And what makes this moment critical is timing. Many companies are still acting as if CBAM might change or disappear. But in reality, the first consequences are already becoming visible in customer conversations. 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. See you in the Podcast, Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

    1 hr

  6. MAR 5

    GN 66 - Turning Dirty Scrap into Golden Castings

    Dirty scrap might look like waste. But inside that messy pile lies one of the biggest opportunities in the aluminum industry. In this episode, hosts Fabian Niklas and Staffan Zetterström talk with Julio Quintero — materials engineer and host of the Dirty Scrap Podcast — about how recycling actually works in practice. From scrapyards to alloy recipes, from sorting technology to geopolitics, the conversation explores how the industry can turn contaminated scrap into high-quality aluminum and why doing it right is not just sustainable, but extremely profitable. What begins as a discussion about recycling quickly evolves into a deeper look at technology, process knowledge, market dynamics, and the uncomfortable inefficiencies still present across the metal supply chain. If aluminum is the material of the future, then scrap might be its most undervalued resource. Key Topics * How dirty scrap becomes high-quality aluminum A step-by-step look at the recycling chain — from scrap collection and sorting to alloying, melting, and casting. * The missing link between scrapyards and secondary smelters Why poor communication across the recycling chain leads to lower recovery rates and lost value. * Why “dirty scrap” still contains massive value How contamination, coatings, and moisture reduce metal yield, and how the right pretreatment technologies can dramatically increase recoveries. * Rotary furnaces, stack melters, and the importance of the right process Why melting technology must match the type of scrap being processed to maximize efficiency. * The surprising economics of scrap vs. primary aluminum Why scrap prices can sometimes exceed primary aluminum due to demand for low-carbon materials. * Can recycled aluminum match primary quality? A discussion about metallurgy, process control, and why secondary aluminum can achieve nearly identical properties with the right practices. * Why do many foundries still waste aluminium? From molten metal literally overflowing onto the shop floor to inefficient melting practices, small operational improvements can unlock significant profit. * The geopolitical reality of aluminum supply Energy prices, tariffs, and global trade tensions are reshaping where primary aluminum can realistically be produced. * Sustainability beyond marketing buzzwords Why true sustainability is not just about CO₂ numbers, but about producing more metal from the same resources. “Make more out of the same” Recycling aluminum is often framed as an environmental issue. But as Julio explains, it is equally a technological and economic one. When scrap is poorly sorted or improperly melted, large amounts of metal are lost as oxides, dross, or emissions. With better processes and smarter technologies, those losses can be dramatically reduced, meaning more usable aluminum from the same raw material. In other words, sustainability and profitability are often the same thing! The challenge is not the availability of scrap. The challenge is whether the industry is ready to handle it properly. Because in a world where aluminum demand keeps growing, learning how to turn dirty scrap into golden castings might become one of the most valuable skills in the entire supply chain. 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. See you in the Podcast, Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

    57 min

  7. FEB 19

    GN 65 - The Next Generation in Casting

    Young researcher Paul Becker brings a fresh perspective straight from the shop floor and the next generation of the foundry industry. The discussion with the hosts Fabian Niklas and Staffan Zetterström explores what it really means to enter a mature, conservative industry at a time of technological disruption and demographic change. From Rheocasting innovation to the aging workforce, from recruitment challenges to social media visibility, this Gold Nugget examines the uncomfortable but necessary questions shaping the future of casting. Key Topics * Why the foundry industry still struggles to attract young talentA closer look at perception gaps, outdated narratives, and why casting often isn’t even on the radar of students. * What it feels like to enter a conservative industry as a young professionalFirst-hand impressions of navigating established structures, traditions, and slow-changing mindsets. * The real challenges behind adopting new technologies like rheocastingWhy innovation is not just about technology readiness, but also about cultural readiness. * Why recruitment in casting still happens “by accident”How many careers in foundries start randomly, and why that approach may no longer work. * The generational shift nobody can ignore anymoreWhat happens when experienced experts retire, and fewer young engineers replace them? * What young professionals actually expect from employers todayChanging priorities around flexibility, purpose, and development opportunities. * Why flexibility beats rigid work models in modern foundriesA discussion around work culture, trust, and what younger talent values in daily work environments. * The surprising role of social media in saving the industry’s futureHow visibility, storytelling, and digital presence influence whether young people discover casting at all. “Without young talent, the industry stands still.” The foundry industry is facing a silent turning point. A retiring workforce, slow recruitment pipelines, and rising technological complexity are colliding at the same time. This episode doesn’t romanticize the problem; it confronts it head-on. What makes this conversation powerful is its honesty. It’s not about buzzwords like innovation or transformation. It’s about mindset. Flexibility, visibility, and openness to new ways of working will decide whether the next generation joins the industry or chooses something else. If you care about the future of casting, this episode is less about listening and more about reflecting. Because the real question is not whether young talent exists. It’s whether the industry is ready for them. 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. See you in the Podcast, Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

    40 min

  8. FEB 5

    GN 64 - Alloys are a Strategy disguised as Metallurgy

    For decades, alloys were treated as fixed inputs. One specification. One melting furnace. One way of doing things. In this Gold Nugget, Fabian Niklas and Staffan Zetterström challenge that thinking and explain why alloys have quietly become one of the most powerful strategic tools in the foundry industry. This conversation is not about chemical limits or phase diagrams. It is about margins, differentiation, supply risk, sustainability pressure, and long-term positioning. Alloys are no longer a back-office engineering decision. They sit right in the middle of business strategy. This episode also marks the start of Goldcasting’s alloy focus for 2026. Not as a trend watch, but as a reality check for anyone who wants to stay relevant in the coming years. Key Topics ✅ Why the era of one alloy, one product is endingHow OEM requirements, sustainability targets, and scrap availability are forcing a wider and more flexible alloy landscape. ✅ Alloy strategy as a competitive moatWhy do foundries that master alloy flexibility raise entry barriers and reduce price-based competition? ✅ Scrap as the real bottleneckWhy access to the right scrap streams may become more valuable than access to primary metal, and why this shifts power in the value chain. ✅ Gigacastings and the myth of extreme propertiesA critical look at elongation targets, real crash performance, and why simpler alloys may already be good enough in many applications. ✅ Trade politics and regulatory pressureFrom tariffs to CBAM and geopolitical tensions, why alloy sourcing is becoming a political and financial issue, not just a technical one. ✅ Special alloys and quiet opportunitiesWhy the most attractive business is often not the biggest volumes, but the applications where knowledge, alloy design, and problem-solving matter. Alloys are not about metallurgy alone; they are about positioning One theme runs through the entire episode: deliberate alloy selection. Designing processes around them. Understanding scrap flows. And using metallurgy as a lever to defend margins instead of eroding them. The industry is moving away from standard alloys, passive supplier roles, and lowest price logic. In their place come specialization, flexibility, and foundries willing to invest in understanding alloys as a strategic asset. This episode also sets the stage for upcoming interviews with experts across recycling, sustainability, primary aluminum, scrap markets, special alloys, and future applications. If you have questions, technical or uncomfortable, send them in. They will shape the conversations ahead. See you in the Podcast,Fabian and Staffan Get full access to Goldcasting 🏆 at goldcasting.substack.com/subscribe

    25 min
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About

Learn how to make money in the foundry industry. Listen to the discussions of Staffan Zetterström and Fabian Niklas. Also enjoy the stories of our Guests. goldcasting.substack.com

Information

  • Creator
    Staffan Zetterström & Fabian Niklas
  • Years Active
    2023 - 2026
  • Episodes
    71
  • Rating
    Clean
  • Copyright
    © Staffan Zetterström & Fabian Niklas
  • Show Website
    Goldcasting Podcast

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