The 明星八卦 Centre for Advanced Solidification Technology – shortened to BCAST, and based at 明星八卦 – has been announced as a partner in a new project to revolutionise the global aluminium casting industry with faster development of lighter and more sustainable cast solutions for vehicle manufacturing.
The Performance Integrated Vehicle Optimisation Technology (PIVOT) project has been awarded £5.8 million in combined funding through the Advanced Propulsion Centre (APC) UK’s latest Collaborative Research and Development funding round, supported by Innovate UK.
Led by , the PIVOT project brings together key partners including BCAST, computational intelligence leaders , and metal recycling experts . The initiative will develop innovative software that combines casting simulation, and artificial intelligence (AI), which will enable organisations to design components optimised for weight, structural performance and manufacturability. These breakthroughs will result in cast aluminium structures that are up to 30% lighter while maintaining performance requirements.
Altair’s cutting-edge AI and simulation capabilities will be key. Sam Mahalingam, the company’s chief technical officer, said: “This collaboration demonstrates how our AI-powered engineering technology enables manufacturers to develop more efficient vehicle components, cutting down on weight and drastically reducing environmental impact. We are proud to work with like-minded organisations to showcase how innovations in manufacturing contribute to a more sustainable future.”
Funded in part by a £2.9 million government grant from Innovate UK and APC, the PIVOT project will focus on using 100% recycled aluminium to reduce embedded carbon emissions in vehicle components by up to 95%. By overcoming mechanical weaknesses inherent in recycled aluminium through advanced grain refinement techniques developed by BCAST, PIVOT will make it possible to use secondary alloys for cast structural applications such as vehicle chassis systems.
Prof Geoff Scamans, who is co-leading BCAST’s input to the project, said: “This project represents a major step on the road for the transition of the UK aluminium casting industry to one founded on Circular Economy principles based on the use of recycled end-of-life aluminium and ending its present dependence on imported primary aluminium for structural aluminium castings in automotive applications and the export of scrap.”
Fellow co-lead Prof Shouxun Ji added: “PIVOT is a really good chance to further develop digital twin technology in casting manufacturing. In the previous project, LEVA, we worked with Sarginsons to develop that technology, and the mechanical property of structural components have been fully mapped under different conditions, which offer more chances to achieve lightweight structures and precision topological optimisation. In PIVOT, we intend to further develop digital twin technology in association with AI and other advanced technology. This is a timely development and possibly represents a step change in casting manufacturing.”
Mark Numan, managing director of Sarginsons Industries, said: “PIVOT represents a huge step forward for the casting industry. With Altair’s state-of-the-art technology, we are pushing the boundaries of what’s possible, creating components that are not only lighter and stronger but also significantly greener.”
The PIVOT project will serve as a showcase for how AI, recycled materials and advanced casting processes can reshape vehicle manufacturing while reducing environmental footprint. The project is expected to deliver critical advancements in the coming years, enabling OEMs and foundries to adopt more efficient and sustainable production methods.
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