Gigacasting opens up new possibilities for structural components

By: Thomas Fritsch, Editor-in-Chief

Interviewees: Federico Montini (Sales Director and Board Member), Valentina Montini (Purchasing Director and Board Member)

The investment in a Gigapresse is of great significance to FOMA from for two strategic reasons. Firstly, this marks our clear entry into the structural components business. We will use this plant to manufacture door frames and other structural components.

Furthermore, in Europe there are currently only a few gigapresses, most of which are installed at OEMs. This scarcity gives us a technological and competitive advantage – Innovation leadership has always been part of FOMA’s DNA.

Our engineering team has also worked closely with the plant supplier to achieve a machine configuration that is as flexible as possible, enabling the production of components with different geometries.

Growth despite a market downturn: diversification as a key to success

The automotive industry is undergoing radical change, with production in Europe on the decline.
How is FOMA’s die-casting business faring in this environment, and what strategies are you pursuing for future growth?

For the year 2025, we expect revenue growth of around 20 per cent, with a further increase of approximately 20 per cent in the following two years. This is remarkable given the decline in vehicle sales in Europe.

This is made possible by our technological openness: We are working on both electric vehicle and internal combustion engine projects. In addition, we have launched new projects in the field of structural components and have entered the commercial vehicle segment. This diversification is a key component of our five-year growth plan.

The limits of gigacasting: realism rather than a race for size

With the new Italpresse plant, FOMA has entered the era of gigacasting.
Are there already plans for further large-scale presses or additional investments?

We are monitoring developments in China very closely, but do not currently see extreme press sizes exceeding 10,000 tonnes becoming relevant in Europe in the short term. We also take a critical view of the long-term economic viability of such ‘giga-presses’.

A trend towards larger machines is evident, but above around 6,000 tonnes this makes sense, in our view, primarily for OEMs. The investment required is enormous, whilst the market is also highly volatile. At FOMA, we are deliberately starting with a single machine, monitoring the market closely and assessing the real-world sustainability of the concept. We do not rule out further gigapresses, but are not currently planning any machines exceeding 5,000 tonnes.

Focus on quality: process stability for large-format components

Large-format structural components place high demands on precision and process stability.
How does FOMA ensure that the highest quality standards are maintained even in gigacasting?

We invested considerable effort right from the early stages of the project. This included additional simulation cycles during mould development, the installation of a sophisticated vacuum system and highly precise temperature control. In addition, we invested in a new computed tomography system.

In collaboration with our quality department, we have developed robust testing processes to monitor density and warpage – both of which are critical factors for structural components. Furthermore, like all die-casting lines at FOMA, our Gigapresse is fully automated, which ensures productivity and repeatability.

High vertical integration as a competitive advantage

FOMA covers numerous processes, including in-house toolmaking and machining.
How important is this level of integration for competitiveness and quality?

Over the past ten years, we have invested over 100 million euros in the expansion of our machining operations. Today, it is essential to supply ready-to-install components – regardless of whether the customer is an OEM or a Tier 1 supplier.

The toolmaking division is historically the origin of FOMA and has been a key source of expertise since the 1950s. Even today, it remains crucial to the efficiency of our die-casting production, as we are able to maintain, optimise and manufacture tools ourselves.

Regulation and technological openness: expectations of policymakers and OEMs

The European automotive industry faces considerable uncertainty, particularly with regard to the ban on internal combustion engines from 2035.
What are your expectations of policymakers and OEMs?

Our first all-electric electric vehicle project was launched back in 2018. Since then, we have implemented numerous EV projects. Currently, however, we are seeing that many of these programmes are falling short of the originally expected production figures.

In the long term, electric mobility will play a central role, but the timeline is difficult to predict. The uptake in Europe is developing more slowly than expected. The planned ban on internal combustion engines from 2035 is, in our view, causing additional uncertainty.

We would like to see greater technological openness so that the market can decide which solutions will prevail. This is the only way to secure investment, innovation and competitiveness in Europe in the long term.