What Hycast does

Hycast AS is a Norwegian industrial technology company founded in 1990 as a spin-off from Hydro R&D and wholly owned by Norsk Hydro ASA. Headquartered in Sunndalsøra, Norway, with over 70 employees and approximately 500 million NOK in 2024 revenue (over 90% from exports, primarily to Asia, Europe, the Middle East, Africa, and the Americas), Hycast designs and delivers advanced, fully automated DC (Direct Chill) casting systems and supporting inline melt treatment equipment for the global aluminium industry. Its core product portfolio centres on vertical casting machines (CMV) paired with proprietary billet casting technologies (LPC Low Pressure Casting and GC Gas Cushion Casting) and rolling slab casting technology (AFM Adjustable Flex Mould), complemented by the Siphon Inert Reactor (SIR) for degassing, Drain Free Filter (DFF) for mechanical filtration, Rod Feeder systems for grain refining, Launder systems, and the RAM alkali metal removal module. The Hycast Insight real-time monitoring system adds computer vision, thermal sensing, and predictive anomaly detection on top of the installed equipment base.

The company monetizes through three primary streams: capital equipment sales of complete casthouse systems and components, recurring service contracts (Basic and Premium support plans with defined response-time SLAs and worldwide on-site support within 72 hours), and spares and consumables sales from a main warehouse in Sunndalsøra plus consignment stock in Shanghai, China. Hycast sells exclusively through direct enterprise field sales with regional managers covering Europe/Middle East/Africa, Asia, and the Americas, targeting large primary aluminum producers and aluminium extrusion companies in a horizontal segmentation approach. The company has conducted long-term research collaborations with NTNU, SINTEF, and IFE, reinvests approximately 5% of annual turnover in R&D, and holds ISO 9001:2015 and ISO 14001:2015 certifications. Its primary customer is the global aluminium industry, with Hydro Sunndal functioning as a 'living laboratory' reference site rather than a dominant revenue contributor.

Name

Hycast

Legal name

Hycast AS

Website

https://hycast.no

Company type

Private

Founded year

1990

Operating status

Operating

Headcount range

51–100 employees

Short description

Hycast AS is a Norwegian industrial technology company that designs and delivers fully automated DC casting systems, inline melt treatment equipment, and real-time monitoring solutions for global primary aluminum producers, generating approximately 500 million NOK in 2024 revenue from over 70 employees.

Ownership category

akta.pro rank

Product category

Industrial Aluminium Casthouse Equipment

NAICS

Alumina and Aluminum Production and Processing (33131), Other Aluminum Rolling, Drawing, and Extruding (331318), Aluminum Sheet, Plate, and Foil Manufacturing (331315), Aluminum Foundries (except Die-Casting) (331524)

SIC

Metalworkg Machinery & Equipment (3540), Nonferrous Foundries (Castings) (3360), Rolling Drawing & Extruding Of Nonferrous Metals (3350), Industrial Instruments For Measurement, Display, And Control (3823)

akta.pro primary industry

Metal Forming & Fabrication Machines (Presses, Bending, Shearing, Stamping) (IMAHADAC)

akta.pro secondary industries

Aluminum Value-Added Components (Automotive, Aerospace, Packaging, Building Systems) (IMAKACAM), Aluminum Rolling (Flat-Rolled Products: Sheet, Plate, Foil) (IMAKACAF), Aluminum Extrusion (IMAKACAG)

Keywords

• Aluminium casting equipment
• Casthouse technology
• DC casting systems
• Melt treatment systems
• Industrial automation

Headquarters

HQ city

Sunndalsøra

HQ country

Norway

HQ region

Europe

Offices2 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Personnel, Technology or R&D, Operations, Supply Chain, Marketing or Sales, Infrastructure

Revenue model

1. Aluminium Casthouse Equipment and Systems: Hycast generates revenue through the sale of advanced aluminium casting equipment and complete casthouse systems. This includes casting machines, melt treatment equipment, and supporting systems. Revenue reported at approximately 500 million Norwegian Kroner in 2024 with over 90% coming from exports.
2. Service and Support Plans: Annual and half-yearly service contracts including operator training, technical support, remote assistance, and on-site support. Premium and Basic support plan tiers available with 24-hour response times and worldwide on-site support within 72 hours.
3. Spares and Consumables: Sale of spare parts and consumables for Hycast equipment. Main warehouse in Sunndalsøra with consignment stock in Shanghai, China.

Pricing tiers

Go-to-market motion1 record

Distribution channels1 record

Marketing channels3 records

Core offering

Hycast designs, manufactures, and supplies advanced fully automated aluminium casthouse systems and DC (Direct Chill) casting technology for the global aluminium industry. Its offering includes vertical casting machines (CMV), billet casting technology (LPC and GC), rolling slab casting technology (AFM), inline melt treatment units (SIR, DFF, Rod Feeder, Launder), crucible alkali metal removal (RAM), and the Insight real-time monitoring system, complemented by service plans, spare parts, and consumables.

Product overview

Hycast delivers next-generation DC (direct chill) casting lines and casthouse technology for the global aluminium industry. The product portfolio centres on fully automated casting systems comprising CMV vertical casting machines paired with either LPC or GC billet casting technologies or AFM adjustable mould slab casting technology. Supporting these core casting systems is a comprehensive suite of inline melt treatment equipment including I-25/I-60 SIR degassing units, Drain Free Filter systems, Rod Feeder grain refining systems, and Launder transport systems. The offering is rounded out by RAM alkali metal removal technology for crucible systems, the Insight real-time monitoring solution with camera robotics, plus comprehensive service, spare parts, and support plan options. Key differentiating attributes include fail-safe design philosophy, safety add-on solutions, and cloud-connected fully automatic monitoring systems with wireless communication, high-resolution cameras, and thermal imaging sensors.

Differentiator

Problem solved

Functional benefit

Products and services

• CMV - Casting Machine Vertical Vertical semi-continuous casting machine featuring single-acting inner-guided hydraulic cylinders and flexible mould support systems, designed for high-quality aluminium billet and slab production in primary aluminium casthouses.
• LPC - Low Pressure Casting Technology Advanced extrusion billet casting technology based on proven GC technology with a validated billet diameter range of 127mm to 520mm for soft and hard alloys, delivering very thin inverse segregation layer and optimised solidification height for high-quality extrusion billets.
• GC - Gas Cushion Casting Technology Industry-standard billet casting technology with diameter range 145mm to 405mm, featuring patented dual graphite ring design for optimised gas-oil distribution, stable surface quality, and high pit recovery rate.
• AFM - Adjustable Flexible Mould Technology Adjustable mould technology for rolling slab casting with fully automatic width adjustment in the 300-400mm range and high precision, eliminating slab tail swelling and reducing mould investment costs.
• I-25 / I-60 SIR - Siphon Inert Reactor Online melt refining, degassing, and inclusion removal system positioned between furnace and casting machine, using bottom-mounted rotors and 100% inert atmosphere; I-25 handles up to 25 tons/hour and I-60 handles up to 75 tons/hour for hydrogen and inclusion removal.
• Launder Systems (L-20, L-45, L-80) Standardised prefabricated launder modules for aluminium flow rates from 7 to 80 metric tons per hour with low thermal conductivity, high mechanical strength, and integrated control systems for customised casthouse layouts.
• RF-2 / RF-4 Rod Feeder System Grain refining system available as RF-2 (two coil cages) or RF-4 (four coil cages), with variable feeding speed of 10 to 1,000 cm/min and frequency converter control to improve mechanical properties and reduce hot-cracking during casting.
• DFF - Drain Free Filter Inline mechanical filtration system for liquid aluminium that supports higher density filter plates (up to 80 ppi) and enables complete draining of the filter box after operation to reduce remelt and operating costs.
• RAM - Removal of Alkali Metals System for efficient removal of alkali metals and carbides in crucible/tapping systems, featuring unique rotor design and AlF3 injection system with customisable configurations for various crucible handling setups.
• Insight - Real-Time Monitoring System Camera robot monitoring system with Wi-Fi communication, HD camera, thermal sensor, and auto-scan mode that removes operators from molten metal hazard zones and provides predictive detection of bleed-outs and casting defects.
• Technical Service & Support Service offering including half-yearly and yearly service plans with operator training, priority telephone support, remote assistance, worldwide on-site support within 72 hours, and additional equipment warranty under Basic and Premium subscription tiers.
• Spares & Consumables Tailor-made equipment lists and spare parts services for Hycast casthouse equipment, with main warehouse in Sunndalsøra, Norway, and consignment stock in Shanghai, China, ensuring stable and secure casthouse operations for customers.

Quantifiable outcome

• No serious injuries recorded in 35 years of operation
• +3 more outcomes

Named customers3 records

Segments2 records

Ideal customer profiles2 records

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

AI capability6 records

Feature9 records

Partnerships

Five partnerships are on record, tiered core and minor.

• NTNU (Norwegian University of Science and Technology)coreStrategic or Co-development PartnerLong-term research collaboration on LPC (Low Pressure Casting) technology development with extensive research conducted at NTNU alongside Hydro R&D.
• SINTEFcoreStrategic or Co-development PartnerResearch institution collaborating on long-term casting technology development including LPC, AFM, and SIR technologies. Also partner in LowEX project for low-carbon aluminium heat exchangers.
• Institute for Energy Technology (IFE)minorStrategic or Co-development PartnerCollaboration since the 1970s developing mathematical models for casting technology, providing foundational research support for Hycast's proprietary technologies.
• Elkem ASA Silicon MaterialsminorStrategic or Co-development PartnerProject partner in the LowEX three-year innovation project for developing low-carbon production value chain and products for aluminium heat exchangers.
• Gränges ABminorStrategic or Co-development PartnerProject partner in the LowEX three-year innovation project for developing low-carbon production value chain and products for aluminium heat exchangers.

Scale indicators8 records

Recent moves8 records

Expansion highlights6 records

Broad incumbents

• SMS group: Large German engineering group active in metals processing, with Hertwich as its aluminum casthouse arm. Comparable as a broad incumbent offering aluminum casthouse solutions within a much wider metallurgical plant portfolio.
• Danieli: Italian-based global supplier of equipment and plants for the metals industry, including aluminum through its FATA division. Comparable as a broad incumbent competing in aluminum casthouse and rolling equipment alongside many other metal-industry segments.

Others

• Norsk Hydro ASA: Norwegian aluminum conglomerate that is both Hycast's 100% parent and a major customer ('living laboratory' at Hydro Sunndal). Comparable only as the parent ecosystem — not a direct competitor — but materially shapes Hycast's R&D pipeline, customer access and strategic direction.

Direct peers

• FATA Aluminum (Danieli Group): Italy-based FATA Aluminum, part of the Danieli Group, designs and supplies aluminum processing and casting plants, including sheet, plate and extrusion billet lines. Directly comparable as a competing supplier of casthouse technology and equipment.
• Otto Junker: German manufacturer of induction melting and casting equipment for non-ferrous metals, including aluminum casthouse solutions. Comparable as a European-based supplier of specialized metal casting and melting technology to industrial metal producers.
• Pyrotek: Global supplier of engineered equipment, consumables and technical services for the aluminum industry, including melt treatment and casting technology. Comparable as an adjacent provider of casthouse equipment and consumables to primary aluminum and extrusion customers.
• Continuus-Properzi: Italian manufacturer of continuous casting machines for non-ferrous metals (including aluminum). Comparable as a specialized supplier of casting equipment serving aluminum and other non-ferrous metal producers.
• Hertwich Engineering: Austrian supplier of complete aluminum casthouse equipment including homogenizing, sawing, and billet casting systems, part of the SMS group. Directly comparable as a turnkey casthouse technology provider serving the same primary aluminum and extrusion customer base.
• Wagstaff: US-based manufacturer of Direct Chill (DC) casting equipment and technologies for the aluminum industry. Closely comparable to Hycast as a specialized supplier of billet and slab casting systems to primary aluminum producers worldwide.

Emerging players

• Insertec: Spanish engineering firm specializing in molten metal treatment, degassing and filtration for aluminum foundries. Comparable as a niche provider of melt-treatment and inline filtration technology that overlaps with Hycast's SIR and DFF product lines.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks6 records

Key highlights7 records

Customer concentration

• LinkedInlinkedin.com/company/hycast

Compliance2 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles3 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Hycast