Sarginsons, Altair and voxeljet to collaborate on PIVOT Project | VoxelMatters - The heart of additive manufacturing

The PIVOT Project, a UK-based initiative, is set to redefine the future of vehicle manufacturing by combining innovation, sustainability, and advanced aluminum casting technology. Led by Sarginsons Industries Ltd, with key partners including Altair, Aston Martin, Brunel University London, and metal recycling experts GESCRAP, the project is supported by Innovate UK and the Advanced Propulsion Centre (APC). It will implement sand binder jetting technology from voxeljet, using inorganic binders to produce the aluminum casts.

At its core, PIVOT aims to develop 100% recycled aluminum components that are lighter, stronger, and more sustainable, reducing embedded carbon emissions by up to 95%. The initiative will integrate metal solidification, digital twin simulation, and topology optimization into one advanced AI-powered software solution.

A PIVOT is combining three critical casting processes into a single software platform. Metal solidification optimizes the cooling and solidification of molten metal to enhance material properties. Digital twin simulation runs precise virtual models of casting processes to predict mechanical strength and performance. Topology optimization allows the design of lightweight yet high-strength structures, maximizing efficiency and sustainability.

By integrating these processes into a unified system, the software will make advanced casting technology accessible to OEM designers and foundries, democratizing the industry and reducing design-to-production cycles.

As part of PIVOT, voxeljet and Sarginsons Industries are collaborating on a Beta Program for the VX1000-S IOB printer, leveraging voxeljet’s cold, inorganic binder jetting 3D printing technology.

Unlike traditional sand casting, which relies on organic binders that release harmful emissions, inorganic binder jetting eliminates volatile organic compounds (VOCs), significantly reducing the environmental impact of metal casting.

This advanced binder jetting process aligns with PIVOT’s sustainability goals. It allows Sarginsons to reduce emissions during metal casting, achieve complex, high-precision designs with unparalleled flexibility, and eliminate harmful residues that could compromise workplace safety.

A key challenge in sustainable casting is the mechanical weakness of secondary aluminum alloys, which traditionally limits their use in structural applications.

To address this, Brunel University London is pioneering grain refinement techniques that improve the mechanical properties of recycled aluminum. By negating the weakening effects of iron and oxide contamination, PIVOT will make it possible to use 100% recycled aluminum for high-performance vehicle structures.

This development will drastically lower carbon emissions, making near-zero-carbon aluminum the industry standard. It will enable OEMs to transition to circular manufacturing, reducing reliance on primary aluminum while enhancing vehicle lightweighting, which improves fuel efficiency and electric vehicle (EV) range.

PIVOT’s final phase will push manufacturing innovation even further by enabling radical and unconventional designs. The project will integrate 3D printing for highly complex geometries, smart cooling and intelligent tooling for optimized thermal management, and designed deformation to create components that self-adapt to stress conditions.

These advancements will revolutionize the automotive industry, making ultra-lightweight, high-performance aluminum castings a reality.

A critical player in PIVOT, Altair (Nasdaq: ALTR) is providing cutting-edge AI-driven simulation and engineering technology. By utilizing machine learning and generative design, Altair’s technology will allow manufacturers to optimize weight and structural performance while maintaining durability. It will also reduce material waste through precise, AI-driven casting designs and develop 30% lighter cast aluminum structures with up to 95% lower embedded carbon emissions.

“This collaboration demonstrates how AI-powered engineering is reshaping vehicle manufacturing,” said Sam Mahalingam, CTO of Altair. “By combining AI, recycled materials, and advanced casting, we are paving the way for a more sustainable automotive future.”

With a £5.8 million investment co-funded by Innovate UK and APC, the PIVOT Project is expected to transform the aluminum casting industry. The project will achieve up to 30% weight reduction in cast aluminum components through innovative manufacturing techniques while cutting embedded carbon emissions by up to 95%. By exclusively using 100% recycled aluminum and eliminating VOC emissions through inorganic 3D printing, PIVOT will set a new industry standard for sustainability.

“This project represents a major leap forward for the casting industry,” said Mark Nunan, Managing Director, Sarginsons Industries. “With Altair’s state-of-the-art AI technology, we are redefining the possibilities of vehicle design—lighter, stronger, and more sustainable.”