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TWDI - Thin Wall Ductile Iron

A casting process & new alloy so ductile iron is 75% thinner so it allows lightweight for EVs and vehicles

June 2020
July 2023
Gallery TWDI - Thin Wall Ductile Iron 1
Gallery TWDI - Thin Wall Ductile Iron 1


The energy to move something is directly dependent on its weight. In order to reduce energy consumption of planes, trains, cars, and more it is necessary to lightweight them by using improved materials. Most solutions for lightweighting drive up costs which is an impediment to adoption. The solution is to develop ductile iron to be able to be thinner. Ductile iron has the best specific strength (strength compared to density) compared to aluminum or steel. It’s use was limited as it would not form under 6mm. Using the environmentally friendly lost foam casting process, innovations in foam blowing technology, a metallurgical alloying process that prevents casting defects, and a new 3D printing process, Skuld's ductile iron can be cast as thin as 1mm. This is 66% thinner than the best world class commericialized casting processes. This process and material enable the redesign of castings, machined components, and weldments made from iron, steel, or aluminum to save weight and cost.

Label Date July 24, 2023
From United States
Maturity stage Prototype testing in the real world
Looking For New clients, Visibility, Funding, Partners, Network, Credibility

The environmental benefits

  • A new design which used ductile iron with a wall thickness of 1.5mm reduced the weight by 75%
  • Our new 3D printing version of the process has shown as thin a 1mm is possible
  • Compared to traditional casting, lost foam casting: 27% less energy consumed 80% less particulate air emissions 37% less greenhouse warming potential gases 7% less raw materials
  • This process uses scrap steel products and recycles them to new parts. - This means it is not necessary to produce steel or aluminum from ore - 1 ton of steel production results in 1.8 tons of carbon dioxide emissions

The Financial benefits

  • On a cost per tensile strength per pound basis, Skuld's solution can save 70% versus iron or steel parts and 66% versus aluminum
  • The process eliminates the need for casting machining - in many cases castings are bought and 50-80% of the material is machined off which can cost $6-8 per pound. Our solutions is net shape.
  • For the same component redesign, the cost per pound went up but the total component cost decreased by 44%.

Activity Region

  • /

North america

United States,

  • Headquarters
  • Activity

Company Profile

Skuld LLC

We develop manufacturing processes in alloys, casting, & 3D printing for more cost effective and efficient metal parts.

View company profile Solution website
Headquarters Springfield, OH 45502, USA

Related Topics

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The information set out above, is solely for the purposes of information and the Solar Impulse Foundation does not provide any guarantee as to its authenticity, completeness or accuracy. This information does not constitute investment advice or a recommendation to buy into, transact or to enter into any agreement with any of the parties or persons mentioned above. Potential investors or interested parties are solely responsible for their investment or business decisions and for performing any due diligence required by the circumstances. The innovator Skuld LLC has asserted ownership of the intellectual property rights for images, videos, and content showcased above, affirming full and unrestricted usage rights, and has provided explicit permission for the Solar Impulse Foundation to publish such information designated as "public" in the application form.