Alliance Casting European Development Centre (ACE-DC)

A consortium of engineers and manufacturers is building lighter, stronger cylinder heads for cars and trucks, using advanced casting techniques to cut fuel consumption and emissions. This matters because vehicle engines waste significant energy overcoming their own weight. Current casting methods limit how thin and complex cylinder heads can be made without weakening them. The project combines Brunel University’s expertise in liquid metal engineering with HAUK’s inorganic 3D core printing technology to produce components that are both lighter and more durable. A new mobile app from Lighthouse Systems will also track production quality in real time. If successful, the technology could improve fuel efficiency and power-to-weight ratios across millions of vehicles, both in the UK and in export markets. The consortium expects to create 23 jobs and safeguard 153 existing roles. Beta Technology Limited will assess the commercial viability of the new products, ensuring the research moves from lab to factory floor. The work is applied, not fundamental science—its value lies in immediate industrial adoption rather than long-term discovery.