GFE is the first process consulting company to introduce a truly innovative wheel manufacturing solution to the global market. As a pioneer in foundry consulting, wheel engineering, and foundry process development, GFE successfully implemented a worldwide innovation in wheel casting technology that sets a new industry benchmark.
The core of this project was the replacement of the traditional steel filter in the sprue area — a component that typically causes contamination of 90–120g sprue weight — with a permanent filter system. This new solution was required to remain process-stable for at least one week, ensuring consistent production performance without negatively impacting mechanical properties. By stabilizing the process and eliminating steel contamination, the sprue material becomes fully recyclable within the customer’s own foundry melting loop, preserving material value and significantly improving sustainability across the manufacturing chain.
The result is a measurable economic advantage: approximately €0.10 added value per wheel, achieved through smarter material flow and optimized casting processes. For OEM wheel producers, AM wheel manufacturers, and global foundry operations, this represents a major step forward in both efficiency and technical excellence.
GFE has not only proven the concept but successfully transferred this breakthrough into full-scale series production. With deep expertise in wheel consulting, wheel development, rim engineering, and global foundry engineering, GFE now offers this technology as a fully customized process improvement project for wheel manufacturers worldwide. This includes comprehensive engineering support, process audits, and implementation strategies tailored to OEM wheels, AM rims, and advanced automotive wheel programs.
With this achievement, GFE strengthens its position as a global leader in wheel development worldwide, delivering solutions that enhance quality, reduce waste, and redefine what is possible in modern wheel casting.
