By: Thomas Fritsch, Editor-in-Chief
Interview partners: Federico Montini (Sales Director and Member of the Board), Valentina Montini (Purchasing Director and Member of the Board)
Entering Gigacasting: A Strategic Step for FOMA
FOMA has recently installed a 4,600-ton die-casting cell from Italpresse – a classic gigacasting system.
What does this step mean for your company, and which components will be produced on this line?
The investment in a gigapress is of strategic importance for FOMA for two main reasons. First, it marks our clear entry into the production of structural components. On this system, we will manufacture door frames and other structural parts.
Second, there are currently only a few gigapresses in operation in Europe, most of them located at OEMs. This limited availability gives us a technological and competitive advantage — innovation leadership has always been part of FOMA’s DNA.
In addition, our engineering team worked closely with the equipment supplier to develop a highly flexible machine configuration, allowing the production of different component geometries on the same system.
Growth Despite Market Decline: Diversification as a Core Strategy
The automotive industry is undergoing major change, and vehicle production in Europe is declining.
How is FOMA’s die-casting business developing in this environment, and what strategies are you pursuing for future growth?
For 2025, we expect revenue growth of around 20%, followed by a further 20% increase in each of the subsequent two years. This is notable given the declining vehicle sales volumes in Europe.
This development is driven by our technological openness. We are working on projects for both electric vehicles and internal combustion engines. In addition, we have launched new structural component projects and entered the commercial vehicle segment. This diversification is a central element of our five-year growth plan.
Limits of Gigacasting: Pragmatism Over Size
With the new Italpresse system, FOMA has entered the era of gigacasting.
Are there plans for additional large presses, and where do you see natural limits to gigacasting?
We closely monitor developments in China, but currently do not see extreme machine sizes above 10,000 tons becoming relevant in Europe in the near term. We are also cautious regarding the long-term economic viability of such systems.
While a trend toward larger machines is clearly visible, beyond approximately 6,000 tons, gigacasting makes sense primarily for OEMs. The investment volumes are substantial, and the market remains highly volatile. At FOMA, we are deliberately starting with one system, observing the market carefully, and assessing the actual sustainability of the concept. Additional gigapresses are not ruled out, but no systems above 5,000 tons are currently planned.
Quality and Process Stability for Large Structural Components
Large-format structural parts place high demands on precision and process stability.
How does FOMA ensure the highest quality standards in gigacasting?
To meet these requirements, we invested heavily at an early project stage. This included additional simulation loops for tool development, the installation of an advanced vacuum system, and highly precise thermal control. In addition, we invested in a new computed tomography (CT) system.
Together with our quality department, we developed robust inspection processes to control density and distortion, both of which are critical parameters for structural components. Our gigapress, like all die-casting lines at FOMA, is fully automated, ensuring high productivity and cycle-to-cycle repeatability.
Vertical Integration as a Competitive Advantage
FOMA covers many processes in-house, including toolmaking and machining.
How important is this level of vertical integration?
Over the past ten years, we have invested more than €100 million in expanding our machining capabilities. Today, delivering ready-to-install components is essential — whether the customer is an OEM or a Tier 1 supplier.
Toolmaking is historically the origin of FOMA and has been a core competence since the 1950s. It remains a decisive factor for the efficiency of our die-casting operations, as it allows us to maintain, optimize, and manufacture tools in-house, particularly for medium-sized press systems. Regulation and Technological Openness: Expectations Toward Policy and OEMs
The European automotive industry faces considerable uncertainty, especially regarding the planned ban on combustion engines from 2035.
What are your expectations toward policymakers and OEMs?
Our first purely electric vehicle project started back in 2018, and since then we have implemented numerous EV programs with OEMs and Tier 1 suppliers. However, many of these projects currently fall below the originally expected volumes.
In the long term, electromobility will play a key role, but the timeline remains difficult to predict. Adoption in Europe is progressing more slowly than anticipated. The planned 2035 ban on combustion engines adds further uncertainty.
From our perspective, technological openness is essential. Markets should be allowed to determine which solutions prevail. Only with this approach can investment security, innovation, and competitiveness in Europe be sustainably ensured.
