CastCalc Osturu Consulting
For Procurement Teams · Iron, Steel & Aluminium Sand Castings

What your castings cost
- and what they should cost
are rarely the same number.

Most procurement teams managing casting spend have no independent view of foundry pricing. CastCalc gives you one - built on real sand casting economics, not industry averages.

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The 4 Hidden Cost Drivers in Iron Casting Pricing
A 60-minute live session showing procurement managers how foundry costs are actually built - and exactly where suppliers have room to move. With real part examples and a live Q&A.
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Free to attend · No recording released · Live Q&A included · Wednesday 11 June 2025
€400M+ casting spend benchmarked across EU
±5–10% benchmark accuracy vs. actual supplier pricing
22 markets with active price data - EU, Asia, Americas
15+ yrs inside foundry operations & supply chain
The problem

Casting pricing is a black box. And suppliers know it.

Foundries quote what the market will bear. Without an independent cost model, procurement teams have no way to tell whether a quote is competitive, whether a price increase is justified, or whether a design change will add or save cost.

The numbers are not abstract. At €5M annual casting spend, a 1% pricing gap is €50,000 left on the table - every year, without knowing it's there.

€50,000

What a 1% pricing gap costs a company spending €5M/year on castings. Most gaps we find are larger - and they compound year on year.

What procurement teams tell us

  • 01 Quotes arrive with no breakdown. You accept or walk away - with no data to negotiate from.
  • 02 Price increase letters cite energy costs with no supporting data. Challenging them feels impossible.
  • 03 Engineering makes design changes without knowing the cost impact until the RFQ comes back weeks later.
  • 04 Two suppliers quote the same part 30% apart. You don't know who's right - or why.
  • 05 New supplier evaluation takes months because you have no internal benchmark to qualify quickly.
  • 06 Comparing EU vs. China vs. Turkey quotes is almost impossible - currency, logistics, quality risk, and overhead structures are all different.
Luka Plahuta
Luka Plahuta
Metallurgical Engineer · MBA
Founder, Osturu Consulting
Why this is credible

I built CastCalc because I needed it - and it didn't exist.

Before I built tools for buyers, I worked inside foundries. I started on the production floor at Livar, one of Slovenia's main iron foundries, and eventually led their quality department - a team of 25 - certified to IATF 16949.

I know what a moulding line actually costs to run. I know how yield loss compounds through a poor gating design, and why two identical-looking parts can carry completely different overhead burdens depending on the foundry's setup.

That experience - combined with an Executive MBA and years of active EU casting sourcing - is what I encoded into CastCalc. It isn't a generic calculator. It reflects how foundry cost engineers actually think.

Production floor, Livar Where it started - hands-on foundry operations
Quality Director, Livar Team of 25+, IATF 16949, automotive supply chain
Executive MBA, Ljubljana AI tools and business development focus
Osturu Consulting Active EU casting sourcing - Italy, Germany, France, Austria and beyond
The insight

Why iron casting prices are so hard to challenge.

Casting cost is a compound problem. Material, yield loss, moulding line performance, overhead allocation - each component is invisible in a standard quote. Here is where the money actually goes.

60–70%

Material & melt cost

The largest component - and the most traceable to market data. Yet most buyers don't track current scrap and alloy prices closely enough to verify what they're being charged on the material line.

3–4×

Yield loss multiplier

A finished part weighing 10 kg may require 30–40 kg of metal poured. Gating systems, feeders, and scrap rates drive this. Design geometry alone can move total casting cost by 15–25%.

22

Markets tracked monthly

Labour, energy, scrap, and alloy prices move differently in Germany versus Turkey versus China. CastCalc tracks 22 markets with monthly updates - so when a supplier claims their costs went up, you can check whether the market data supports it.

Services

Two ways to work together.

A one-time portfolio audit for teams who want an immediate picture of where they stand, or an annual platform subscription with ongoing expert access for teams building a permanent benchmarking capability.

One-time engagement
Casting Cost Audit

A structured, expert-led review of your casting portfolio - focused on spend, price benchmarks, design cost flags, and a concrete action plan. Delivered as a written report.

What is included
  • 80/20 spend analysis - identify which parts drive the most cost
  • Independent price benchmarking across your key parts vs. current EU market rates
  • Design-for-cost observations - advisory ideas, no DFM sign-off
  • Quality and specification risk flags
  • Written report with benchmark data and a prioritised action plan
  • 30-minute debrief call to walk through findings
From €1,800
Scoped to portfolio size · excl. VAT
Typical delivery: 3–5 working days after data receipt
Request an audit
Annual subscription
CastCalc Annual

Full platform access - calibrated to your suppliers, updated monthly with real market data, and backed by 10 hours of direct expert consulting each year.

What is included
  • Unlimited access to the CastCalc cost engineering simulator - iron, steel, aluminium, 3D sand printing
  • 22-market price coverage - EU, Turkey, USA, China, India, Japan and more
  • Custom moulding-line presets calibrated to your key suppliers
  • My Parts portfolio tracker - save your parts, get monthly price recalculations automatically, download reports
  • Monthly market-based price updates - scrap, energy, alloys across all covered markets
  • 90-minute onboarding workshop, live, for your team
  • 10 hours of annual consulting - design reviews, RFQ support, cost studies
  • Engineering design workshop - DFM fundamentals for sand casting
  • Priority technical support throughout the year
Pricing on request
Structured to your team size, supplier scope, and modules required.
Discussed on the discovery call - not a fixed package.
Book a subscription call
Materials: Iron (grey & ductile) · Steel · Aluminium · 3D sand printing incl. low-volume & manual moulding

Markets: Slovenia · Germany · Italy · Austria · Czech Rep. · Poland · Croatia · Serbia · Hungary · Romania · Bulgaria · BiH · Sweden · Finland · Spain · Portugal · France · USA · Turkey · China · Japan · India
Also included in CastCalc Annual

Know your packaging and logistics costs before the part exists.

Upload a 3D model of your part and CastCalc calculates exactly how many pieces fit in a container - accounting for both volume and weight limits. You get packing density, units per shipment, and logistics cost per piece before tooling is ordered.

For procurement teams evaluating new parts or new suppliers, this eliminates one of the most common late-stage surprises: discovering that logistics cost makes an otherwise competitive quote unworkable.

Book a call to see it live
Packaging & Logistics Calculator
Container type 20ft standard
Part weight 12.0 kg
Part volume (from STL) 4.2 L
Units per shipment 1,840 pcs
Logistics cost / piece €0.43
Calculated from uploaded .STL file · Weight and volume limits applied
Insights

Casting cost intelligence - in plain language.

Short articles for procurement managers who buy iron, steel, or aluminium sand castings and want to understand what's actually driving supplier pricing - without needing a metallurgy degree.

See all 6 articles →

The 4 Hidden Cost Drivers in Iron Casting Pricing

A 60-minute online session designed for procurement managers who buy iron, steel, or aluminium sand castings and want to understand how foundry pricing is actually built - so they can negotiate from a position of knowledge.

  • How material, melt, and yield loss compound into the €/kg you see on a quote
  • Why two foundries in the same country quote the same part 25% apart
  • EU vs. Turkey vs. China vs. India - how to compare cross-market quotes on equal terms
  • What a price increase letter actually reveals - and what to ask for in response
  • How design geometry drives cost - three real part examples
  • Live Q&A with Luka Plahuta - bring your actual parts and questions

Reserve your place

📅  Wednesday, 11 June 2025 ⏱  10:00 - 11:00 CET 🎥  No recording released - live only 💰  Free to attend
No spam. Just the date confirmation and a reminder.
How it works

From first contact to negotiation leverage.

01

Webinar or discovery call

Attend the live webinar or book a 30-minute call. We review your situation and where the biggest opportunities are.

02

Audit or onboarding

One-time portfolio review with a written report, or platform setup calibrated to your specific suppliers.

03

Independent benchmark

You receive €/kg data for your actual parts - built on real foundry logic, not industry averages.

04

Negotiate with data

Use the benchmarks in supplier meetings, price increase responses, RFQ comparisons, and budget planning.

CastCalc showed a meaningful accuracy gap where our previous reference tool significantly overestimated cost on larger parts. The CastCalc benchmark landed within 5% of our actual supplier pricing - which is exactly what we need to negotiate with confidence.

Procurement team · Bondioli & Pavesi, Italy - Annual CastCalc subscriber since 2025
Next step

Find out what your castings should cost.

Attend the free webinar, or book a direct 30-minute call. Either way, you will leave with a clearer picture of where your casting spend stands.

Or reach us directly: sales@osturu.com  ·  +386 70 275 682

Frequently asked questions.

Who is CastCalc for?
Procurement managers and supply chain teams at European manufacturing companies that buy iron or steel castings regularly - typically €1M or more per year. Companies between 100 and 2,000 employees where procurement has real accountability for cost.
Do you publish the subscription price?
Discussed on the discovery call - it depends on the number of users, which supplier presets need calibrating, and which modules you need. We don't sell a fixed package because the value depends on your portfolio. The conversation takes 30 minutes and you'll have a clear number at the end of it.
What materials does CastCalc cover?
Grey iron, ductile iron, steel, and aluminium - all via sand casting processes. 3D sand printing (binder jetting) including low-volume and manual moulding lines is also covered, not just automatic. CastCalc is built specifically around sand casting economics, not die casting or investment casting.
How accurate is the benchmark?
Typically ±5–10% versus actual supplier pricing for standard iron parts. Accuracy improves significantly once the moulding-line presets are calibrated to your specific suppliers - which is part of the onboarding process.
What does the Casting Cost Audit deliver?
A written report covering your top spend parts, independent price benchmarks vs. current EU market rates, design-for-cost observations, quality risk flags, and a prioritised action plan. Plus a 30-minute debrief call to walk through findings.
Can I start with the audit and move to the subscription?
Yes - that is a natural path. The audit identifies where the biggest opportunities are. The subscription gives you the tools to capture them on an ongoing basis.