February 2026 Volume 8

EQUIPMENT & TECHNOLOGY

TURNKEY FORGING LINES FOR LIGHTWEIGHT ADVANCED MATERIALS By Karissa Krueger

T he automotive industry is in the midst of a profound transformation. Electrification, sustainability mandates, and consumer expectations for improved fuel efficiency are reshaping vehicle design and manufacturing. At the center of this evolution lies a critical engineering challenge: lightweighting. Reducing vehicle weight is no longer optional; it’s essential for meeting stringent emissions standards, extending battery range, and enhancing overall performance. Every kilogram saved translates into measurable gains in efficiency, whether for internal combustion engines or electric vehicles. For EVs specifically, lightweighting directly impacts battery size and range, making it a cornerstone of modern automotive manufacturing. Achieving these benefits without compromising strength and durability requires advanced materials such as aluminum and high-strength steels, combined with precise manufacturing processes. Forging has emerged as a key technology for lightweighting as it delivers superior mechanical properties, fatigue resistance, and dimensional accuracy. However, producing lightweight components at scale introduces new complexities, including tighter tolerances, intricate geometries, and the need for rapid cycle times. These challenges demand a new approach — one that integrates technology, automation, and process expertise into a single solution. This is where turnkey forging lines become imperative.

Inside a Modern Forging Line A turnkey forging line is much more than a collection of machines. It is an integrated ecosystem designed for efficiency, consistency, and adaptability. These lines combine presses, automation, furnaces, and digital controls into a seamless workflow that minimizes downtime and maximizes output. Take the production of lightweight aluminum suspension or chassis components as an example. Billets must be heated to precise temperatures, pre-formed where necessary, and transferred quickly and reliably through multiple forming stages. Any disruption — temperature variation, mistimed handling, or positioning errors — can affect part quality and scrap rates. In a turnkey line, these steps are synchronized through automation and digital monitoring, allowing high-volume production without sacrificing consistency. Automation is the backbone of these systems, but different applications call for different solutions. Conventional industrial robots offer flexibility and are often cost-effective, but they can become a bottleneck in very high-output lines. More advanced solutions, such as mono beam and walking beam systems, provide faster and more precise handling, making them ideal for crank and screw presses. At the forefront of automation technology is the Tri-Axis Servo Transfer system developed by ANDRITZ Schuler. This system delivers maximum positioning accuracy and reliability, enabling optimized forming, cooling, and spray processes. Servo-driven solutions reduce cycle times without compromising quality, making them particularly well-suited for automotive lightweighting programs where precision and speed are paramount. Real-World Impact The benefits of turnkey forging lines are not theoretical — they are already delivering results in forge shops worldwide. One notable example is the GLF 5,000-ton turnkey line developed for a Tier 1 supplier. This fully automated system followed the successful implementation of a GLK 2,500-ton turnkey line for the same customer. Both lines are in operation and have increased the manufacturer’s production capability for several aluminum suspension parts, including wishbones, swivel bearings, and similar forgings. Operator involvement is minimal, limited primarily to monitoring, thanks to advanced automation and digital controls. The result is consistent quality, reduced scrap, and faster time-to market, demonstrating the transformative potential of turnkey solutions.

ANDRITZ Schuler is a one-stop, one-source supplier for forging presses, hammers, and counter blow hammers, process and operational development, dies, and automation systems.

FIA MAGAZINE | FEBRUARY 2026 12