SPINKO Aluminium Castings for High-Speed Rail: Weight and Carbon Footprint Reduction in Modern Rail Transport

Growing demands for social mobility, climate goals, and the pursuit of greater energy efficiency are among the key challenges facing the railway sector today. This is especially true in the high-speed rail segment, where every kilogram of saved weight translates directly into measurable operational and environmental benefits. In response to these needs, Spinko provides advanced solutions in the form of aluminium castings manufactured using HPDC (High Pressure Die Casting) technology.

Lightweight Components = Significant Savings

Aluminium is a material with a density of just one-third that of steel. This difference allows for significant reductions in the total weight of rail vehicles. Lighter trains require less energy for acceleration and braking, impose lower loads on infrastructure—such as tracks, bridges, and platforms—and exert less pressure on wheelsets, which reduces their wear and extends the time between maintenance intervals. Ultimately, this results in lower operating costs and a reduced environmental impact.

In the context of high-speed rail—where every split second, kilowatt-hour, and tonne matters—aluminium has become the material of choice. Its properties make it possible to not only improve train acceleration but also enhance passenger comfort, safety, and vehicle lifespan.

SPINKO – Precision, Quality, Innovation

With years of experience in aluminium die casting, Spinko is fully prepared to supply structural components for modern rail units: from body elements (e.g., undercarriage parts, mounts, structural reinforcements) to interior systems (handles, joints, seat frames, etc.).

Our HPDC castings feature: high dimensional precision, the ability to create complex geometries, excellent repeatability, durability and corrosion resistance.
 

HPDC technology enables the production of thin-walled yet highly durable parts, ideal for applications where mass reduction is essential without compromising structural rigidity and safety.

Aluminium and Ecology – Responsibility Starts with the Material

For Spinko, sustainable development is more than a slogan—it’s a commitment. Our HPDC aluminium castings are made from recycled alloys, significantly reducing the carbon footprint of the production process. Notably, aluminium can be recycled repeatedly without losing its mechanical properties or quality, making it ideal for a circular economy.

Additionally, all waste generated during the casting process—including excess material, sprues, and other technological scrap—is entirely remelted and reused in our facility. This minimizes waste, reduces the use of virgin materials, and contributes to the development of a more responsible industry of the future.

Looking Ahead: Magnesium Alloys

In pursuit of even more innovative solutions, Spinko is also considering the implementation of magnesium alloy casting. Magnesium is approximately 35% lighter than aluminium while offering similar mechanical properties. Its potential use in railway applications represents a further step toward ultra-lightweight constructions that could revolutionize the design of modern train units.