Speed and efficiency. Goals that drive change in most industries, but are particularly pertinent in the automotive trade, as car manufacturers look to reduce production timescales and minimise costs.
Aluminium die casting has long been the preferred manufacturing method for the car industry – and with a global aluminium die casting market valued at USD 82.67 billion in 2022, estimated to reach over USD 144.74 billion by 2030, it’s no surprise that auto diecasting methods are evolving.
Which is just one of the reasons why Giga Presses have been hitting the headlines this year.
Whether you’ve heard of the Giga Press and are keen to learn more or it’s completely new to you, here we take a closer look at this latest development in manufacturing and what it means for the advancement of aluminium die casting in car production.
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What is a Giga Press?
Put simply, a Giga Press is a gigantic aluminium die casting machine.
The idea behind it is to use the press to make large parts – such as vehicle underbodies – and switch out smaller components. Using a Giga Press could replace more than 50 components with just one.
The desired outcome being that by simplifying the process, both time and resources spent on construction will be reduced.
The latest – and largest – Giga Press currently available is the size of a small house and has an impressive clamping force of 9,000 tonnes. This dwarfs the likes of Bühler Real-Time Closed Loop Control Diecasting machines, which have a locking force from 160 to 1,300 tonnes.
So, what’s the issue?
On paper this all sounds good – so why aren’t all vehicle makers seeking out the Giga Press?
Aluminium is already favoured in car production and aluminium die cast parts are used for all manner of car components, including braking systems and under-bonnet instruments.
A study commissioned by European Aluminium shows that the average aluminium content in European-produced cars rose to 179 kilograms in the three years to 2019, and is expected to increase to almost 200 kilograms by 2025.
Why aluminium is the go-to metal for the automotive industry
Aluminium is widely used in car production, favoured for:
- Reduced weight – strong but with a low density, aluminium is a lightweight metal, and reducing the weight of a vehicle by 15% can have a knock-on effect of improving its fuel economy by 25%.
- Less waste – aluminium is easily recycled, ensuring waste is kept to a minimum, which helps both the environment and company budgets.
- Enhanced appearance – finishing treatments for aluminium die cast parts are not always necessary, helping to increase savings and reduce timescales.
If it’s not the metal putting companies off, it must be the method.
Aluminium die casting is already the favoured process for mass-producing parts for the automotive industry, but many brands are reluctant to supersize to the Giga Press.
The biggest fear, it seems, is the risk of encountering costly mistakes.
Critics have hit out at the Giga Press, raising concerns about the potential for a negative impact on quality. Switching smaller parts out for one larger component also poses a bigger threat if things go wrong.
Finding a flaw will mean replacing the full unit. With smaller individual parts, more flexibility is afforded. This makes resolving the issue less problematic – and less expensive – than it would be with one large part.
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Talk to die casting experts
At Lupton and Place, we’ve worked with numerous prestigious automotive brands over the years, including BMW, Toyota, Saab, Jaguar, Scania, and Iveco.
With extensive in-house capabilities and knowledge of die casting in the automotive industry, we’re well placed to offer expert advice on the most suitable die casting options for all elements of car part production.
If you’d like to discuss the production of aluminium die cast car components in more detail, please don’t hesitate to get in touch with the team. You can call us today on 01282 422361, email info@lupton-place.co.uk, or fill in our online form and we’ll get back to you shortly.