Revolutionary Solutions for EV Components

The meteoric rise of electric vehicles (EVs) has sparked an urgent demand for lightweight, precision-engineered components. To stay ahead of this trend, Alupress GmbH, a leader in aluminium and magnesium die-casting, has embraced cutting-edge shot blasting technology.The company recently installed a continuous feed spinner hanger blast machine, custom-built by Rösler, to streamline production. This solution not only meets the demand for speed and efficiency but also ensures delicate handling to protect the integrity of intricate components.

Aluminium is the material of choice for EV components, thanks to its low bulk density, which helps extend battery range. However, the production of thin-walled, complex designs like those used in control device housings, demands precision processing. At Alupress’s Brixen facility in Italy, meeting the automotive industry’s stringent standards required a new approach to shot blasting, one that balances robust performance with gentle treatment of fragile parts.
A Seamless Automated System

Key to Alupress’s upgrade was an automated, all-encompassing solution. The shape and wall thickness of their aluminium and magnesium castings required a de-flashing process that is both efficient and gentle to avoid warping. Rösler’s continuous feed spinner hanger blast machine, paired with a power & free transport system, delivers on all fronts. After blasting, components are cleaned, quality-checked, and packaged—all with minimal manual intervention.

Alupress’s long-standing partnership with Rösler was instrumental in this decision. The proven reliability of Rösler’s machines and their expertise in processing delicate components provided the confidence to invest in this advanced technology.

Engineering Innovation to Prevent Warping
The model RHBD 13/18-So machine is equipped with eight 11 kW turbines featuring extra-wide throwing blades. These turbines create a broad blast pattern and are strategically placed on both sides of the chamber to ensure equal force distribution. This duplex configuration minimizes the risk of distortion while maintaining high throughput.
Another ingenious feature is the oscillating workpiece carrier. Capable of holding 60 to 80 components, the carrier rotates and moves back and forth during blasting to ensure comprehensive cleaning, even in undercuts and hard-to-reach areas. This precision engineering ensures flashes and burrs are removed without compromising the structural integrity of the components.

Safety, Ergonomics, and Efficiency
Rösler’s system emphasizes operator safety and comfort. An adjustable carrier height at the loading station provides ergonomic working conditions, reducing strain on employees. Safety mats around hazardous areas enhance protection without the constraints of traditional enclosures or sensors.
Buffer zones in the transport system further optimize production, allowing continuous operation during employee breaks. Maintenance is simplified with strategically placed connections for cleaning equipment and a wet dust collector compliant with ATEX standards, ensuring optimal performance and dust control.

Driving the Future of EV Component Production
With its investment in Rösler’s advanced shot blast technology, Alupress is setting new benchmarks in EV component manufacturing. By seamlessly integrating speed, efficiency, and precision, this innovative solution meets the growing demands of the automotive industry while safeguarding the delicate designs of tomorrow’s EVs.