Engineering, simulation and consulting for aluminium low-pressure die casting wheel manufacturing (LPDC) worldwide.
Global Foundry Engineering GmbH
Stahlhofen · ManisaNew on Amplifa
About GFE Group
Global Foundry Engineering GmbH (GFE) is a European engineering and consulting company headquartered in Stahlhofen (Westerwald), specialising in the manufacture of aluminium cast wheels. The company offers complete wheel development for OEM and aftermarket — from 3D wheel design and FEA and casting simulation through to technical validation and production readiness. In addition, GFE supports aluminium foundries and wheel manufacturers worldwide with LPDC process optimisation, scrap reduction, quality improvement, supplier development and interim management. In the materials field, the focus is on the AlSi7Mg and AlSi11Mg alloys; simulations are carried out with CATIA V5, ANSYS and LS-DYNA. Customers include companies from the automotive industry (OEM), the aftermarket and the light metal casting sector in more than 12 countries, including Europe, Asia, India, the Middle East as well as North and South America. The company was founded in 1954 as an iron casting business and is today a third-generation family business.
- Site
- Stahlhofen
- Processes
- Alloy Wheel Engineering, Wheel Development, FEA Simulation, Casting Simulation, Wheel Design, Technical Validation, Foundry Consulting, Production Consulting
- Materials
- Alloy Wheel, Aluminium, AlSi7Mg, AlSi11Mg
- Certificates
- Cornering Fatigue Test, 13° Impact Test, Bidirectional Fatigue Test, Modal Analysis
- Founded
- 1954
- Employees
- 4
- Industries
- Automotive industry (OEM), Aftermarket / wheel trade, Aluminium foundries / light metal casting, Motorcycle parts (KTM)
- 01
3D wheel design (CATIA V5)
- 02
Weight optimisation AlSi7Mg/AlSi11Mg
- 03
FEA/casting simulation (ANSYS, LS-DYNA)
- 04
Technical validation
- 05
3D casting mold design
- 06
LPDC process optimisation / Foundry Consulting
- 07
Supplier development for casting capacities
- 08
Interim Management / Turnaround Support
Materials & Processes
AlSi7Mg
Aluminium casting alloy for weight-optimised wheels in the OEM sector.
AlSi11Mg
Aluminium casting alloy for wheels with a focus on castability and manufacturability.
Locations
Stahlhofen
DEHead office
- Materials
- Aluminium (AlSi7Mg, AlSi11Mg)
- CATIA V5
- ANSYS
- LS-DYNA
Manisa
TRWheel Development & Research Center at the Techno Camp of Manisa Technical University
- Materials
- Aluminium (AlSi7Mg, AlSi11Mg)
- CATIA V5
- ANSYS
- LS-DYNA
Components & Services
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Alloy Wheel EngineeringEngineering | – | – | – | – | Alloy Wheel |
| Wheel DevelopmentEngineering | – | – | – | – | Alloy Wheel |
| FEA SimulationEngineering | – | – | – | – | Alloy Wheel |
| Casting SimulationEngineering | – | – | – | – | Alloy Wheel |
| Wheel DesignEngineering | – | – | – | – | Alloy Wheel |
| Technical ValidationEngineering | – | – | – | – | Alloy Wheel |
| Foundry ConsultingEngineering | – | – | – | – | Aluminium |
| Production ConsultingEngineering | – | – | – | – | Aluminium |
| Process-ConsultingEngineering | – | – | – | – | Aluminium |
| LPDC Process OptimizationCasting | – | – | – | – | Aluminium |
| Foundry EngineeringEngineering | – | – | – | – | Aluminium |
| MachiningMachining | – | – | – | – | Aluminium |
| Surface TreatmentSurface | – | – | – | – | Aluminium |
| QualityTesting | – | – | – | – | Aluminium |
| Process analysis and optimizationEngineering | – | – | – | – | Aluminium |
| Foundry / Machining / PaintingOther | – | – | – | – | Aluminium |
| Modal AnalysisEngineering | – | – | – | – | Aluminium |
| Cornering Fatigue TestTesting | – | – | – | – | Aluminium |
| Impact TestTesting | – | – | – | – | Aluminium |
| Bidirectional fatigue TestTesting | – | – | – | – | Aluminium |
| 3D Mold designCasting | – | – | – | – | Aluminium |
| wheel castingCasting | – | – | – | – | Aluminium |
| Aluminium LPDC wheel castingCasting | – | – | – | – | Aluminium |
| wheel manufacturingOther | – | – | – | – | Aluminium |
Additional services
Quality & Simulation
GFE validates wheel developments computationally with defined simulation services: Cornering Fatigue Test (ANSYS, approx. 5 hrs), 13° impact test (ANSYS/LS-DYNA, two impact points), Bidirectional Fatigue Test and Modal Analysis. No certificates are listed.
| Evidence | Manisa |
|---|---|
| Cornering Fatigue Test | |
| 13° Impact Test | |
| Bidirectional Fatigue Test | |
| Modal Analysis |
History
- 1954
Founded by Georg Philippi as an Eisenbießerei (iron foundry) in the Westerwald region
- 1985
Jürgen Philippi joins the family business; later international experience in wheel and rim manufacturing
- 2007
Focus on global foundry consulting, foundry process optimisation, aluminium wheel engineering and industrial solutions
- Heinz-Georg
Shift of the business towards aluminium components for mechanical engineering and the automotive sector (year not specified)