Carsten König, Head of Machining Technology and Digital Products at GROB, initially began his career in turning and milling at the age of 16, progressing from conventional machines to advanced 5-axis CNC machining centers. After 3½-year of apprenticeship, he was appointed shift supervisor in the CNC milling shop, overseeing seven 4-axis machining centers and leading a team of five. His role demanded end-to-end responsibility for keeping production running at all times - ranging from repairs, NC programming, spindle replacements, and fixture design to hands-on problem-solving. After nearly two years, Carsten returned to education and enrolled in a technical college for mechanical engineering. During his studies, he completed his practical training with his current employer, marking the start of a long-term professional association.

Following graduation, he joined the company as a machining expert in the commissioning department, a role he held for one year before moving into proposal engineering. Over the next five years, he worked on projects ranging from standalone 5-axis CNC machining centers to fully automated heavy-duty manufacturing lines valued at up to €250 million - significantly expanding both his technical and strategic expertise.

Alongside his engineering career, Carsten deepened his business and economic knowledge by earning a Master Professional Degree (CCI) through evening and weekend studies, further strengthening his ability to bridge technology and commercial strategy.

AL Circle: Can you tell us briefly about your products and services with a focus on aluminium casting solutions.

Carsten König: GROB is a solution provider for CNC machining and automation systems, serving a wide range of industries. One of our core and largest customer segments is aluminium casting.

Our product portfolio for aluminium casting solutions includes highly flexible 4- and 5-axis machining centres, ranging from single-spindle machines to twin-spindle and four-spindle solutions, enabling efficient and precise machining of cast aluminium components. In addition, we offer additive manufacturing printers for rapid prototyping and the production of spare parts, as well as assembly equipment for small part assemblies on aluminium components, such as rivets, plugs, and thread inserts. Comprehensive automation solutions for part handling within manufacturing processes and digital tools for OEE and quality monitoring and continuous improvement complete our product offering. Alongside our products, GROB provides a broad range of services. These include engineering of our own machines and systems, as well as engineering and consultancy for complete manufacturing processes. We support customers with OEE improvement programmes for existing production lines and offer retooling and retrofit solutions to upgrade and extend the lifetime of installed equipment. Together, our products and services enable end-to-end, efficient, and future-proof manufacturing solutions for aluminium casting applications.

AL Circle: With lightweighting gaining urgency across automotive ICE, EVs, aerospace, consumer electronics and renewable energy, how do you assess the growth potential of the aluminium die casting market in 2026 and beyond?

Carsten König: From our perspective, the aluminium die casting market shows strong and sustained growth potential in 2026 and well beyond. This development is primarily driven by the global push for lightweighting, accelerating electrification, and the increasing need for more efficient and sustainable manufacturing processes.

Based on current market analyses, the global aluminium die casting market was recently valued at around USD 73 billion and is expected to reach approximately USD 126 billion by 2032, reflecting a solid long-term growth trajectory. We see a continuous increase in aluminium content per vehicle, not only in electric vehicles but also across modern ICE platforms. In addition, demand from aerospace, consumer electronics, and renewable energy applications are further supporting market growth.

From our point of view, structural innovations such as mega- and giga-castings represent a key accelerator for the market. Integrated aluminium die-cast structures enable part consolidation, weight reduction, and cost efficiency—capabilities that are becoming increasingly critical for OEMs globally. As a result, we expect continued investments in new casting capacities, advanced machining technologies, automation, and digitalisation throughout 2026 and the years that follow.

AL Circle: Digitalisation and automation are transforming every stage of aluminium manufacturing, including casting. How have smart technologies reshaped operational efficiency, quality control and decision-making at your facilities?

Carsten König: GROB has been developing its own software portfolio for nearly ten years. While it initially focused on GROB equipment, it has since evolved into an open platform capable of monitoring other machines, equipment types, and control systems. Our COSERA solution covers MES/MOM functionalities, machine-level performance monitoring, OEE analysis, and predictive maintenance. With our digital solutions from GROB-Net⁴Industry, customers benefit from the production and engineering expertise of a machine tool builder—if required, even without operating GROB machines.

AL Circle: Aluminium casting is an energy-intensive process, with electricity consumption averaging around 2.3 kWh per kg of cast product. What concrete measures are you implementing to reduce energy intensity and improve overall process efficiencies with a view on more sustainable solutions?

Carsten König: Energy efficiency has been a key focus for many years. This starts with the production of our equipment and continues through the use of energy-efficient motors, LED lighting, and highly efficient machine operating modes, such as standby functions. These features are considered standard configurations in our machines.

AL Circle: Could you highlight some of the key milestones and technological or operational achievements your company has accomplished in aluminium casting over the past few years?

Carsten König: We entered aluminium machining early, in parallel with the automotive industry’s transition, and have been part of this shift for decades. We implemented the first high-volume cylinder head and cylinder block machining line using MQL cooling. GROB was also the first machine tool builder to machine subframes and cradles on twin-spindle machines. Our most recent milestone is the G920F⁵, designed for underbody components within giga casting applications, enabling simultaneous machining with two spindles on one or two workpieces.

AL Circle: Which end-user industries do you expect to be the primary demand drivers for aluminium casting products in 2026 and the years ahead, and why?

Carsten König: We expect the automotive industry to remain the primary demand driver for aluminium casting products in 2026 and beyond, as it continues to represent the largest end-user market for aluminium die cast components.

Both electric and conventional vehicles are increasing their use of aluminium castings to meet requirements related to lightweighting, range optimisation, safety, and cost efficiency. In particular, EV-specific vehicle architectures are accelerating demand for large, integrated aluminium die-cast components, such as chassis and body structures. The global market for EV chassis integrated die casting is projected to grow from approximately USD 751 million today to around USD 2.6 billion by 2030, underscoring the strong momentum in this segment.

Beyond automotive, we also expect additional demand growth from aerospace, consumer electronics, and renewable energy industries, where aluminium castings are valued for their strength-to-weight ratio, thermal performance, and recyclability. Nevertheless, driven by electrification, platform consolidation, and high-volume production, the automotive sector will continue to account for the dominant share of aluminium casting demand in the years ahead.

AL Circle: What are your most successful markets right now? What are some challenges that you are facing in your established markets for aluminium?

Carsten König: We are the world’s leading turnkey machining and assembly system provider for the automotive industry, and maintaining this position remains a key objective. Our performance is closely linked to vehicle sales, OEM investment behavior, and developments in powertrain and vehicle structures. Currently, the industry is investing less in new equipment compared to the past decade. In addition, we observe increasing competitive pressure from Chinese manufacturers, which is affecting traditional OEMs and, consequently, our customer landscape.

AL Circle: What are some of the new markets you are targeting for expansion in the near future?

Carsten König: Aerospace has become our second-largest and fastest-growing industry in recent years. Nearly half of our single-spindle CNC machining centres have been sold into this sector, and further expansion in aerospace remains a clear strategic objective.

AL Circle: As one of the biggest events on casting, and one of the first major events in 2026, how was Euroguss for you? Are you participating in any other similarly big events this year?

Carsten König: We were exhibiting at Euroguss for the third time, and we plan to return in two years. There is no other event where we can meet such a large number of automotive customers in one place. It is an excellent platform to discuss new developments, market conditions, and to strengthen industry networks.