A New Departure in Uncertain Times
“Hello and welcome from IDRA.” With these words John Stokes opens his retrospective on the past few years in die casting – a period he calls “breathtaking, even gigantic.” Since EUROGUSS 2018, the last in-person show before the great GigaPress hype, the industry has evolved at a pace that has surprised even seasoned insiders.
From Pioneer Project to Industrial Standard
What began in 2019 as a bold experiment is now a fixed element of modern vehicle architectures: gigacastings – single-piece, lightweight structural components produced in presses exceeding 9,000 t clamping force.
The GigaPress keeps us competitive not only in pure EV programs but also in hybrids and even ICE platforms, Stokes emphasizes.
More than 2.5 million vehicles equipped with IDRA under-body castings are already on the road, turning what was once a niche process into serial production.
More Than Just Under-bodies
IDRA is thinking far beyond floor pans. Stokes points to rear and roof modules that can likewise be cast in one piece. The payoff: fewer parts, lower logistics and tooling costs, and improved crash performance thanks to fewer joints.
Sustainability as an Innovation Driver
Circularity remains a core argument. Enhanced melting and filtration technology now lets IDRA pour fully recycled aluminium while still achieving highest-integrity parts. “This system,” Stokes says, “can be a key building block for a CO₂-optimised factory of the future.”
Looking Forward
As IDRA approaches its 80-year anniversary, the CEO issues a call for collaboration: We want to keep working closely with body-in-white teams at the OEMs. The journey has only just begun.” IDRA, he adds, will stay “at the forefront” in unlocking new applications and refining manufacturing technologies.
An Invitation to Dialogue
Stokes closes with an open invitation: “We look forward to welcoming you at IDRA soon. If you have any questions, please let us know.”
His conclusion could not be clearer: gigacastings are no longer a vision – they are lived industrial reality, fundamentally reshaping die casting.
