Tag: press and stamping

Production minimalism: How Megacasting is reshaping automotive manufacturing

Single aluminium components replace hundreds of welded parts as Tesla's gigacasting revolution spreads to Volvo, Toyota and Chinese manufacturers, promising dramatic cost cuts but demanding massive capital investment.

Ilkhan Ozsevim

Tesla's Nevada Semi surge gathers pace

With a colossal stamping press now in place at Gigafactory Nevada, Tesla primes its all-electric heavy-duty truck for broader output, challenging diesel dominance in a sector ripe for decarbonisation.

Ilkhan Ozsevim

How flexibility, digitalisation and workforce agility are reshaping auto manufacturing

From multi-powertrain assembly lines and digital twin-enabled operations to agile supply networks and adaptive workforce models, OEMs and suppliers are redesigning the production floor for a future that rewards flexibility and responsiveness.

GM promotes Mike Trevorrow to head global manufacturing, align with EV and software shift

General Motors has appointed Mike Trevorrow to oversee global manufacturing and engineering operations, unifying leadership to drive faster industrialisation of software-defined and electrified vehicles across 110 sites.

Inside Tesla’s ‘radical’ manufacturing shift: How the “Unboxed” process could slash EV production costs and impact the automotive industry

As Tesla gears up to launch its $25,000 electric car, its “Unboxed” manufacturing process draws both praise and scepticism. AMS explores its potential to transform automotive production and its implications for the industry.

As VW cuts back in Germany, Slovakia and Spain emerge as new pillars of cost-effective and future-focused production across Europe

As VW’s traditional German plants face uncertainty, its long-established facilities in Bratislava and Pamplona are stepping into the spotlight—producing top-selling models and gearing up for a new era of electric vehicles.

ArcelorMittal’s Multi Part Integration enhances vehicle manufacturing with reduced costs, better flexibility, and improved safety, offering a scalable solution for the automotive industry.

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with ArcelorMittal.Philippe Aubron, Head of Global Automotive at ArcelorMittal explains how the automotive producer’s Multi Part Integration (MPI) solves multiple manufacturing challenges and assists automakers to cut costs and exceed critical targets.

Nissan to amplify green steel usage in Japan by 500% aligning with global automakers in pursuit of carbon neutrality by 2050

In an important move towards enhanced sustainable production, Nissan has declared a fivefold increase in the utilisation of green steel in its vehicle manufacturing. The initiative is part of the OEM’s wider carbon neutrality targets and reflects a growing industry trend.

VW Wolfsburg plant kicks-off Tayron production with precision and digital innovation

The VW main plant is once again producing four different models. After the Seat Tarraco is phased out, the VW Tayron is taking its place. Read how the start-up worked here.

Gestamp employs gigastamping and advanced material solutions to drive lightweighting and sustainability

The Spanish supplier believes it is well prepared for the transformation of the automotive industry. Innovations from a wide range of areas are intended to help. The company presented some of these at the IZB in Wolfsburg.

BMW conquers Mexico with sustainable production at San Luis Potosí: "It's about more than cars"

The BMW factory canteen in San Luis Potosí serves cactus salad made from nopal leaves – harvested in the gardens on the factory premises. An example of the site philosophy: using local resources, promoting sustainability and delivering the highest quality.

Watch now: How to maximise efficiency in battery tray manufacturing and integration

This webinar showcased innovative, cost-efficient quality processes to assure 100% quality in battery manufacturing. New quality solutions from Hexagon enable automakers to detect defects efficiently and ensure a perfect fit into the underbody of the car.

How VW’s Palmela plant excels with lean production, in-house 3d printing, and 90% automation to produce the T-Roc while preparing for the next generation of vehicles

While the continued existence of German VW plants is being questioned, Volkswagen Autoeuropa in the middle of Portugal is operating at a good capacity. Here’s a look at the lean principles that ensure that the T-Roc plant is running so well.

Megacasting: a new frontier or unfounded flare-up for automotive production?

From Tesla to Volvo, Megacasting is gaining traction. While it offers efficiency and sustainability benefits, challenges remain. Stellantis, however, remains unconvinced.

Ilkhan Ozsevim

Watch Now: Next-Gen Gapfillers: Henkel’s Blueprint for Automotive Electronics

This webinar explored Henkel’s latest innovations in thermal gap fillers, designed specifically for automotive electronics.

Gestamp signs agreement with Acciaieria Arvedi for the supply of low-emissions steel

Gestamp will return high-quality steel scrap from stamping parts production to Acciaieria Arvedi, who will reprocess and reintroduce it into the production cycle.

Virtual production networks are able to solve multi-level complexities across automotive manufacturing

Virtual production networks provide automotive manufacturing with myriad solutions like advanced time- and cost-saving simulations, global collaboration capabilities, and innovative tools like digital twins to harness untapped production flexibility.

BMW opens its first North American press shop at Spartanburg and unveils the new BMW X3

BMW Manufacturing celebrates 30 years in Spartanburg with the opening of its first North American press shop and the debut of the fourth-generation BMW X3. The $200M investment will create over 200 jobs and pave the way for electric vehicle production by 2026.

Exclusive: BMW Group improves efficiency with additive manufacturing gripper

BMW Group has improved the speed, versatility and sustainability of its manufacturing and cut costs by using 3D-printed bionic robot grippers. Automotive Manufacturing Solutions reports on the latest innovations from the BMW Group Additive Manufacturing Campus and manufacturing plant in Munich.

How the Audi Q6 e-tron series is proof of the OEMs flexible and sustainable vehicle production ecosystem

Audi’s Ingolstadt plant pioneers sustainable manufacturing with net-zero emissions, showcasing flexible integration and cutting-edge technology: Q6 e-tron leads the way

Changing dynamics– developing the next generation of vehicle architectures

Building electric vehicles has demanded big changes in OEM production operations and increased support from tier suppliers. Gestamp’s director of R&D North America, Paul Belanger, shares some insights into the company’s development and how it’s managing the engineering challenges around EVs

“Our future viability is not a given”: BMW Leipzig’s plant manager Petra Peterhänsel

Despite the crises, the BMW plant in Leipzig is optimistic about the future: in an interview, plant manager Petra Peterhänsel explains how investments in electrification and automation should contribute to a rosy future for the location

Watch Now: Shaping the future: How electric vehicles are driving manufacturing decisions

Dive into the intricacies of EV platform design with industry experts from Gestamp and ArcelorMittal. Looking at how current trends are influencing manufacturing processes and the balance between innovation, sustainability, and efficiency.

Tata subsidiary TPEM launches first Tata-branded vehicle and kicks off production at new Gujarat facility

Tata Passenger Electric Mobility (TPEM) has launched its parent company - Tata’s, first ever own-brand vehicle to mark the inauguration and opening of TPEM’s new vehicle production facility in Sanand, Gujarat, with clear indication of growth in the region.

Gestamp joins Catena-X to push digital and decarbonisation strategies

Gestamp has joined the Catena-X data-sharing platform, which is designed to increase visibility in the supply chain and improve the flow of parts and materials.

Hyundai and Georgia Ports Authority mark first Metaplant shipment

Hyundai Motor Group Metaplant America (HMGMA) and Georgia Ports Authority have marked the first shipment of parts for the EV manufacturing Metaplant under construction in Bryan County.

BMW’s aspirations to the X degree in Spartanburg: Special series

The carmaker is investing in capacity, suppliers and people to prepare for EV production in South Carolina, with a focus on flexibility, resiliency and sustainability. Interviews with the plant CEO, Dr Robert Engelhorn, and key leaders in battery, logistics and training outline BMW’s huge ambitions in the region.

Master of complexity in Spartanburg

Dr Robert Engelhorn is leading transformation of BMW’s operations in Spartanburg, South Carolina for EV production, whilst ensuring manufacturing and workers remain highly flexible in managing vehicle variations and market changes.

AMS Summer 2023 – JLR goes electric

In our AMS Summer digital edition, we have features on JLR’s plans to transform its end-to-end industrial system, ready for new electric models, Seat’s technical upgrades to production operations and upskilling the workforce and insights into developments at Audi’s Neckarsulm plant, and more.

Forming innovations – press shops get smarter

Digital tools are playing a major part in innovating every area of production. The press shop is no exception, with data gathering and AI increasing the visibility and efficiency of the forming process

GM and Mercedes-Benz both sign up for green steel

Both General Motors (GM) and Mercedes-Benz have signed agreements for the supply of green steel for the production of their vehicles.

General Motors to invest $1 billion in Flint ICE truck plants

GM will expand the body shop and assembly, and add stamp and press tooling at its plants in Flint, Michigan, as part of a major investment in the production of internal combustion engine trucks alongside EV investments.

A friend of flexible lines – upgrading JLR production for EVs and more

Barbara Bergmeier is driving digitalisation, sustainability and resilience across JLR’s operations. Now she will help ramp up EV and battery output whilst keeping manufacturing flexible

Watch: Structural change – Developing vehicle architectures optimised for EV manufacturing

Transitioning to build electric vehicles in high volumes is an engineering challenge for OEMs and suppliers, but one that also presents opportunities in manufacturing processes and efficiencies.

Form and function: Developing production processes and structures for electric vehicle architectures

As much as we read about battery cell development and production, in parallel the new electric vehicle architectures are also continuing to evolve as vehicle makers strive to find the optimum balance between platform flexibility to meet changing market demands for new models, while also being viable for high-volume production. To get some insights in to this ongoing process AMS spoke with Paul Belanger, Gestamp’s R&D Director for North America

Jaguar Land Rover to invest in UK manufacturing plants to ramp up EV and flexible production

JLR will invest billions over the next five years to upgrade its UK plants for an electric-first future, including transforming Halewood into an all-electric plant, adding an electric Jaguar in Solihull, producing electric drives and battery packs in Wolverhampton and expanding stamping in Castle Bromwich

Stellantis allocates BEV-centric STLA Large vehicles to Cassino Assembly Plant

The Cassino plant in Italy produces premium vehicles for Alfa Romeo and Maserati

Gestamp announces fourth hot stamping line in India

Gestamp has announced its fourth hot stamping line in India at the 16th edition of Auto Expo 2023- Components

Multi part integrated BIW solutions and advanced steel grades support EV production

PARTNER CONTENTThis content was paid for by ArcelorMittal and produced in partnership with Automotive Manufacturing SolutionsArcelorMittal Global R&D Head of Automotive Steel Solutions, Jérôme Favero discusses how the company’s Multi Part Integration solution is an innovation that has been driven by the challenging context of Battery Electric Vehicle production

Honda Alabama starts production of all-new Pilot

Honda’s Alabama plant requires substantial production changes to build all-new Pilot SUV

AMS Evolution Munich – Building Europe’s EV production network

Senior executives and leading experts from across the automotive manufacturing space came together at the AMS Automotive Evolution Europe summit in Munich, on 7 December 2022 to discuss the many challenges and opportunities surrounding vehicle production. With Russia’s war in Ukraine raging on, a cost of living crisis gripping countries around the world, and supply chain issues with semi-conductors lingering, the backdrop for the event appeared troublesome. And while these topics were often referenced, the transition to electrification was consistently highlighted as the most difficult challenge for carmakers, suppliers, battery producers, and technology providers alike

Ford fitting out Rouge plant to quadruple F-150 EV output after sales stampede

The use of automated guided vehicles instead of a traditional assembly line format is a key enabler in the aggressive production ramp-up Ford is implementing.

Watch: Emerging Press-Hardening Steels and Coatings Contribution for Reduced Weight and CO2 Emissions

Watch this webinar recording to learn and discover how PHS concepts can be profitable regarding CO2 emissions and weight saving and discover the wealth of opportunities from Arcelormittal new generation of steels and coatings for hot stamping.

What Vorsprung durch Technik means for Audi manufacturing in 2022

Digital over physical: Audi is making progress in production through virtual reality, AI and software prototype builds, modular assembly, quality control and energy conservation. AMS gets a tour of manufacturing digitalisation in Ingolstadt, and learns what keeps production chief Gerd Walker up at night.

3D printing: a step closer to mainstream production

Additive manufacturing technologies are now established as useful tools right across the automotive manufacturing sector. But inhibiting factors to their increased adoption include both their limitations in volume applications and a more misplaced perception that they cannot make highly robust parts

The die is cast for Volvo’s future EV production

One of the key pillars of Volvo’s investment in electric vehicles will be the application of aluminium megacasting to produce large structural parts. Mikael Fermér, solution architect for vehicle platforms at Volvo Cars, explains the significance of this change for EV production.

The application of AI

One company where the concept of artificial intelligence (AI) is not futuristic or speculative, but a key element in real manufacturing development and application projects is Audi.

Watch recording: Multi Part Integration, a new approach for simplified and optimized body structures using breakthrough laser welded blanks & patch solutions

Watch this session to discover the groundbreaking Multi Parts Integration concept developed by ArcelorMittal Global R&D and Tailored Blanks.Multi Part Integration (MPI) is designed to incorporate many parts into one laser welded blank (LWB). MPI uses press hardenable steels (PHS) and hot stamping LWB technology to create the single part. The goal is to simplify production for OEMs.

Volvo Trucks buys Chinese manufacturing site to expand heavy duty truck manufacturing

As part of the company’s broader plans to develop global reach, Volvo has acquired Chinese truckmaker JMC Heavy Duty Vehicle to produce and sell more heavy-duty trucks in China.

Watch: Vehicle lightweighting rises to the top of the agenda for designers and engineers

This livestream investigates how designers and engineers at Ford, Gestamp and key suppliers are using innovative materials and creating lightweight architectures, including for models like the Ford F-150 Lightning and Maverick compact truck.

Watch webinar: S-in motion® smart steel solutions for PHEV

Watch this session to discover how ArcelorMittal’s new S-in motion® customizable steel solutions for Plug-in Hybrid Electric Vehicles (PHEV) enable carmakers to meet their sustainability and design challenges at the most affordable cost, with special focus on the IIHS side impact crash requirements and the H-Frame

Audi introduces closed-loop systems for aluminium, wastewater and plastic

Audi has detailed how it is introducing closed-loop systems to its plants as part of its goal to make all its five plants carbon-neutral by 2025. This includes aluminium, wastewater and a pilot project for chemical recycling of plastics.

Toyota pursues dip-free plating technology innovation

The new, more efficient and compact process reduces waste in plating solution during electronic component production

Proof of concept: LA-based start-up Canoo gets production ready

AMS gets under the skin of Canoo’s EV concept to discover how the design became a production ready vehicle

Coronavirus live blog: OEMs set resumption timelines and health protection regimes

Steel makes the case as the mainstay material for vehicles

With OEMs demanding vehicle-structure materials that are low in mass, crash-protective and economic to use, steel grades stay true to form

AMS on Africa: Part 4 – Morocco aims for a million

Volumes in Morocco have steadily climbed to the point where it may soon be the biggest vehicle producer in Africa

Toyota tops up US investment

Toyota has completed its US plant modernisation project, first announced in January 2017, with an additional $700 million for its Indiana facility

Al around the weld

Joining aluminium parts gives the bodyshop a number of challenges not encountered when welding steel. But a variety of weld techniques are helping OEMs to adapt and extend use of the lighter metal

Drawing attention: aluminium hot form quench

Better known as a niche process for parts with deep-drawn and complex geometries in high-strength aluminium, hot form quench is now being adapted for high volume production.

Hot on the press

The need for lightweight, high-strength steel parts has been given a boost with increased production of electric vehicles. AMS reports on a new hot stamping process designed to meet this demand

Challenging relationships

As the trend of electrification gains pace, and demand in the global new car market dwindles, suppliers are looking at ways to best serve their OEM customers

Looking after ‘the triplets’

The Toyota-PSA venture combines talents for the production of a trio of city cars. Gareth Price reports

Mapping out an eastward shift

After many decades of vehicle production, the heartlands of European automotive manufacturing are undergoing a shift eastward. Highlighting the investments, innovations and impact, Ian Henry looks at a group of nations in a region that’s ramping up…

New horizons

With a healthy automotive supply chain and financial incentives on offer, Slovakia was an attractive prospect for JLR to expand its production facility network, as Nick Gibbs reports

Big vehicles, big profits

Pickup trucks and SUVs drive profits and investment in US automotive production as cars are cut from model line-ups

Staying on track

FCA’s restructuring has proved successful and the Jeep brand continues prosper with new models on the way, but there are still challenges to overcome

Supplier financials a cause for concern

Recent quarterly results from some of the major tier ones make for grim reading, as company after company reports declining profits and cites common themes for these disappointing times

Special deliveries

The deployment of automated guided vehicles (AGVs) in automotive manufacturing applications is now well-established. Mike Farish reports on some of the latest developments

Have EVs reached a tipping point in the UK?

With the continued political uncertainty from the lack of Brexit progress, JLR’s announcement of a £1bn investment in its Castle Bromwich facility to make the new electric XJ will be met with some relief by the UK government

Canada feels the chill

Trading challenges and dwindling investment is putting Canada’s automotive manufacturers under pressure

Team building at Hyundai, Czech Republic

Gareth Price reports on a collaborative approach to production quality that prompted Hyundai to locate assembly of its N performance brand in the Czech Republic

A flexible solution

Metal-component supplier Gestamp outlines the challenges ahead and its strategy for meeting higher demand for lightweight parts

Hitting the reset button

US plants – stick or twist?

Working from home

Muscovite foresight

Corolla confidence

Casting a duo

Two innovative metal forming techniques could have a significant impact on the press shop of the future

Smartly pressed