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The team at Munro & Associates take an exclusive behind-the-scenes tour of IDRA’s facilities in Italy—home of the massive 9,000 Ton Giga Press. If you’re an automotive or EV enthusiast, then this tour is a rare deep dive into how cutting-edge die casting technology is reshaping vehicle manufacturing.
The 9,000 Ton Giga Press, part of IDRA’s Neo range, isn’t just a bigger machine—it’s a symbol of a paradigm shift in both automotive and die casting industries. Let’s break down the tour highlights and why this matters for the future of lean design, manufacturing efficiency, and vehicle safety.
IDRA’s Neo Range: The Rise of Giga Presses
IDRA’s Neo series includes machines ranging from 5,000 to 9,000 tons of clamping force, with the Giga Press models at the top. These presses are central to modern automotive strategies, especially in electric vehicle architecture. Rear underbodies, which are more crash-safe compared to front underbodies, have become prime targets for giga-casting. With finer grain structures from fast cooling, new alloys promise strength—but also demand careful crash management.
How IDRA Tests the Giga Press
At the Italian facility, IDRA performs only dry tests due to aluminum casting restrictions. Machines undergo simulated cycles and soak tests—lasting 28 to 48 hours—to validate performance. Post-validation, the presses are disassembled, crated, and shipped to customers worldwide. To justify the investment, customers typically need production volumes between 20,000 to 50,000 parts annually.
Redefining Hydraulics: From OLCS to 5S
Traditional hydraulic systems like OLCS (meter-out control) have served well for decades. However, the Giga Press demanded a radical rethinking. High-speed injections created cavitation risks—air pockets that implode and damage hydraulic systems. To address this, IDRA engineered a new “5S” injection system featuring regenerative hydraulics.
Instead of wasting oil back into tanks, the 5S system recirculates hydraulic fluid through accumulators. A small high-pressure pump maintains flow, saving around 55% in energy costs. The design not only boosts sustainability but ensures critical dynamic force—like squeezing the last bit of toothpaste from a tube at industrial scale.
Managing Mass and Motion: Toggle Mechanics
At 9,000 tons, stopping a moving mass is a bigger engineering challenge than getting it started. IDRA uses a mechanical toggle linkage—essentially a massive spring system—to close and lock the press with precision. When the press closes, it over-travels about 6 millimeters, stretching massive bars that act as energy absorbers.
The toggle system multiplies the cylinder’s force roughly 20–24 times, minimizing stress during operation. Vibropads and elastic joints actively manage vibration by absorbing shock forces between the hydraulic tanks, significantly reducing the risk of structural damage during rapid stops.
Injection Speeds and Cycle Improvements
The fill time—the time it takes to inject aluminum into the die cavity—is crucial. The 6,000 Ton Giga Press achieves fill times around 120 milliseconds. The 9,000 Ton press is estimated at 180–200 milliseconds based on simulations. However, customers are demanding faster fill times to enhance part quality and production efficiency, prompting continuous innovation in valve design and hydraulic tuning.
Smart Design: Hollow Platens and Modularity
Traditional platens were solid castings, but IDRA redesigned them for the Giga Presses. Hollow ribbed structures now provide better strength-to-weight ratios. Crucially, by moving the cores externally, IDRA improves dimensional accuracy during casting, simplifying machining and reducing scrap.
This modularity means IDRA can standardize machining patterns and pre-manufacture components while castings are still being finalized—slashing lead times and allowing future upgrades. A platen can now be swapped 10–20 years later to reconfigure the machine for new vehicle models.
Assembly and Global Expansion Capacity
During the tour, Sandy observed that IDRA’s Giga Press facilities are running at about a third of their true capacity. Currently, IDRA can build six machines at once across their expanded bays. Parts are sourced mostly within Italy—leveraging a dense network of machining specialists—and machines are grouped and staged to 80% readiness before occupying floor space. Final assembly happens either at IDRA or on-site with customers, maintaining lead times under 12 months.
The Broader Impact: A Paradigm Shift for Die Casting
IDRA’s innovation isn’t just about bigger machines—it’s about smarter, leaner, more sustainable manufacturing. The regenerative hydraulics, modular platens, and optimized mechanical linkages all reflect Munro’s core philosophies of lean design and continuous improvement.
As automotive OEMs shift toward large castings to simplify vehicle architectures and reduce assembly costs, they now face a pivotal opportunity. By adopting the 9,000 Ton Giga Press, they can reshape how they design and build vehicles for the future. This game-changing colossus represents a once-in-a-generation opportunity to reshape how cars are made.
IDRA’s Giga Press Tour Takeaways
- Energy Efficiency: IDRA’s regenerative hydraulic system cuts energy costs by 55%.
- Cycle Speed: Faster fill times and cycle optimizations boost throughput.
- Lean Design: Modular platens future-proof the machines and simplify retooling.
- Global Scaling: IDRA’s assembly capacity supports aggressive EV growth targets.
Discover the Future of EV Manufacturing
Interested in more teardown insights, lean engineering analysis, and the future of EV manufacturing? Then check out our expert breakdowns at Munro & Associates and follow our ongoing coverage of industry-changing technology like the IDRA Giga Press. Stay ahead of the curve with the leaders in lean design.