Improving safety and performance has always been on the agenda for Aluminium casthouses. In Hydro, and thus at Hycast, our vision for safety is “no personnel in hazard zones”. As we see it, this implies that all situations and tasks involving personnel in proximity of molten metal should be avoided. This will require new technology. There is a huge potential of improving both safety and performance in the design of new casting lines. Recently Hycast has started to utilize digital twins in the design phase, where process models are linked to the control system allowing for virtual commissioning. In this keynote, some of the recent technology developments within Hydro and Hycast will be presented. This includes visual systems for cast monitoring and bleed out detection, robot sampling for chemistry analysis (OEM) and digital twins of complete casting lines.