Sustainable aluminum solutions for the future of manufacturing

Industrial manufacturing is under more pressure than ever before: products must be high-performance, economical to manufacture, and sustainable at the same time. In this challenging environment, aluminum is becoming an increasingly important material—especially when it is processed in a resource-efficient manner and used efficiently throughout its entire life cycle.

KAISER Aluminium-Umformtechnik supports its customers in the development and manufacture of sustainable aluminum components – exclusively based on drawings or in co-engineering processes, not as standard products. As a specialist in die forging, KAISER offers a manufacturing process that is not only highly precise, but also material- and energy-efficient.

Aluminum as a key material for sustainable industry

Aluminum is considered the material of the future in many industries—and for good reason:

• Lightweight: Reduces energy consumption in mobile applications (e.g., automotive, aviation, medical technology)
  
  
• Corrosion resistant: Long-lasting performance even in demanding environments
  
  
• Recyclable: Aluminum can be reused as often as desired without any loss of quality.
  
  
• Easy to shape: Perfect for complex, resource-efficient component designs
  
  

In practice, this means that those who design with aluminum can reduce weight, save resources, and improve their carbon footprint—while maintaining the same technical performance.

Sustainability begins with the manufacturing process: systematic drop forging

Unlike casting or milling processes, die forging does not alter the material through removal or melting, but rather through controlled forming—with minimal waste and maximum material utilization.

At KAISER, this process takes place as follows:

• Precise and dimensionally stable – thanks to targeted fiber orientation
  
  
• Energy efficient – thanks to optimized temperature control
  
  
• Repeatable accuracy – for small to medium-sized series
  
  
• Resource-efficient – thanks to lower material consumption compared to machining processes
  
  

CNC machining and optional surface finishing (e.g., anodizing, powder coating) result in components that are not only functional but also durable and recyclable.

No standard solutions – only customized manufacturing based on customer drawings

KAISER does not offer off-the-shelf components. Every aluminum forging is created based on customer data—whether 2D drawings, 3D models, or joint development projects.

Typical areas of application in which our customers request sustainable aluminum solutions are:

• Connecting elements in lightweight construction
  
  
• Housing parts for medical devices or mechanical engineering
  
  
• Structural components, such as chassis components, in the automotive sector
  
  
• Components with special requirements for corrosion protection or durability
  
  

Aluminum recycling: More than just an ecological argument

A particular advantage of aluminum is that it is fully recyclable. Today, many industrial aluminum alloys are already made from secondary aluminum, which requires around 95% less energy than primary production.

KAISER also takes this aspect into account:

• Use of recyclable alloys, provided approved by the customer
  
  
• Advice on material-appropriate design to enable subsequent recycling
  
  
• Manufacturing processes with minimal material loss
  
  

For us, sustainability does not stop at the factory gate – it is considered part of a future-oriented production chain.

Conclusion: Responsible aluminum solutions – precise, sustainable, customized

Sustainable manufacturing is not a trend, but a necessity. The use of aluminum in combination with the drop forging process results in high-quality, durable, and resource-efficient components—developed and manufactured according to customer specifications.

KAISER Aluminium-Umformtechnik stands for sustainability without compromise – and for responsible manufacturing.

Precision that works. Forged part by forged part.