Frank Gensty

Innovative Lightweighting | Nemak Global

Schaffhausen, Schaffhausen, Switzerland

About

Technology executive with a proven track record in automotive, aerospace, and mechanical engineering. Expert in system development, industrialization, and innovation leadership, driving transformation from concept to market-ready solutions. Core Competencies: • Strategic Technology & Innovation Leadership • Global R&D Organization Development • Digitalization, Data Analytics & AI Integration • Lightweight Design, Giga-/Hypercasting, E-Mobility • Sustainable Engineering & Bionic Design Mission: Turning cutting-edge technologies into scalable, sustainable solutions that create measurable business impact. #ExecutiveLeadership #AutomotiveInnovation #DataAnalytics #VehicleTechnology #LightweightDesign #TechnologyScouting #EMobility #CastingSolutions #SheetMetal #Extrusion #AIIntegration #GigaCasting #HyperCasting #NVH #Crash #Fatigue #BionicDesign #SustainableEngineering

Experience

  • Global Product Engineering Director at Nemak Global
    Feb 2026 - Present · 6 mos

  • GF Casting Solutions ()
    • Vice President Technology
      Jan 2022 - Feb 2026 · 4 yrs 2 mos

      Contributed to the development and execution of the division’s global technology and innovation strategy, with a focus on e-mobility, mega-casting, and sustainable lightweight solutions Co-led the transformation of R&D structures by establishing Advanced and Series Engineering teams and integrating materials/process expertise into early-stage development Implemented AI-based methods in product industrialization, reducing project launch times by 50% and porosity from 11% to 5% Introduced advanced simulation and casting systems, enabling large components at lower pressure and securing major strategic orders Developed HPDC-based chassis and electric engine housing innovations Drove sustainable material strategies, achieving 80% recycling, 50% CO₂ reduction, and 30% lower energy consumption Establish a global innovation management system with structured ideation campaigns and cross-plant technology field definitions

    • Head of Strategic Operational Projects
      Jul 2020 - Dec 2021 · 1 yr 6 mos

      Led strategic transformation projects to increase operational efficiency and digital maturity Introduced lean and Kaizen initiatives to reduce lead times and improve process stability Developed a global project management method to harmonize technical standards across sites

  • Director Business Development & Project Management at Albert Handtmann Metallgusswerk Gmbh & Co. KG
    Aug 2017 - Jun 2020 · 2 yrs 11 mos

    Developed new business areas in e-mobility and structural die casting Managed complex customer projects from acquisition to SOP Winner of the European Die Casting Award for an innovative rear axle beam with integrated cavity design

  • Director Engineering Automotive Structures at Constellium
    Jul 2013 - Jul 2017 · 4 yrs 1 mo

    Led development of crash-relevant aluminum structures for premium OEMs Introduced simulation-driven development processes to reduce prototype cycles Collaborated with global R&D teams to industrialize next-generation lightweight concepts

  • Vice President Project Management at Linde Hydraulics
    Apr 2011 - Jun 2013 · 2 yrs 3 mos

    Successfully led the carve-out of Linde Hydraulics during Weichai’s €738M investment in KION, ensuring business continuity and operational independence Standardized project management practices across divisions and implemented global training programs Managed cross-border technology transfer projects, including electric motor and hydraulic system integration Coordinated strategic initiatives across engineering, operations, and finance to align with new ownership structure and growth targets