TF Toggle Free HPDC Die Casting Machines

Italpresse Gauss - die casting solutions
Die Casting Machines and Cells
High pressure die casting machines
TF Two Platen Toggle Free Die Casting Machines

Closing force from 1000 to 5700 tonnes

Two platen toggle free machine

SC 3.0 shot end system for absolute injection precision and speed

Compensates for geometrical imperfection of the die and its thermal expansion, making it extremely flexible

Key features

The TF toggle free die casting machines are reliable, rigid and flexible.

Reliable: the absence of the connecting rod system and the reaction platen makes the structure leaner, reducing the number of wear parts.

Rigid: the bigger and shorter tie bars make the machine extremely rigid, ensuring greater die closure for improved casting quality and minimal scrap rate.

Flexible: thanks to 4 independent nuts, the TF die casting machine is able to compensate for geometrical imperfection of the die and its thermal expansion, adapting to different working conditions.

Compact: reduced footprint with the same closing force as the die casting machines with toggle.

Quality: high quality machine construction, made of forged or cast steel platen with coating to increase hardness, and special steel alloy tie bars.

Precise: equipped with SC 3.0 shot end system to maintain absolute consistency and repeatability of the shot, ensuring highest quality of the casting.

The TF die casting machine can be supplied as an automated solution: a fully automated cell that integrates all peripheral devices, from the furnace to automatic deburring with pieces ready for machining.

Applications

Toggle free high pressure die casting machines are ideal for a diverse complex casting production and when the die is frequently changed.

Some applications include:

Automotive parts: Engine blocks, gearboxes, oil sumps, engine support, structural parts (battery housing, car roof, shot tower, pillars).

Other industries: Radiators for household heating, escalator steps, chassis and components for electronic devices, telecommunication components, household appliances, electric motors.

Our Toggle Free series offers the latest technology in high pressure die casting and is ideal for foundries looking for reliable and efficient production of high quality aluminium castings.

The TF series of toggle free die casting machines includes a wide range of models with closing forces from 1000 to 5700 tonnes.

The TF two platen die casting machines are compact, flexible and extremely efficient. The hydraulically driven closing force keeps the machine steady, ensuring more precise closure of the die, minimising scrap rate and ensuring highest quality of the casting.

Discover our TF5700

Our biggest TF machine installed to date..more to come

Flexible and solid for greater productivity

TF's high repeatability increases your plant's productivity and reduces scrap rate.
Thanks to 4 independent nuts, the TF die casting machine is able to compensate for geometrical imperfection of the die and its thermal expansion, adapting to different working conditions.
Enhanced hydraulic system provides greater reliability and uptime at your site. Rock-steady, rigid and solid performance ensures consistent production and on-time delivery of high quality castings to your customers.
Reduced footprint with the same closing force as the toggle machines ensures optimisation of space at your foundry.

Reliable and LEAN for optimal performance

The leaner structure of the machine reduces wear on parts which leads to reduced maintenance costs and increased uptime.
Our friendly and reliable support services, operator training and foundry technology service agreements will help you optimise your productivity and performance.
Our control system and easy to use operator panel comply with the latest standards minimising complexity, and ensure the highest precision.

Supplied with HMe

All HPDC (high pressure die casting) machines are supplied with HMe, a machine control system with advanced data management and diagnostics capabilities. HMe offers real-time storage and powerful analysis of machine and process data, as well as the integration of peripheral and mobile devices. It opens up the possibility of controlling the whole die casting process holistically through a single user interface.

Quality and solid reliability as standard

Our TF machines are built using forged or cast platens made of only certified alloy steel to ensure absolute quality. All our platens have additional coating for increased hardness, greater resistance to wear and to prevent lubricant damage.

Tie bars are made of special steel with a rolling thread - state of the art technology for higher tie bar strength.

Absolute injection precision

Equipped with the SC 3.0 shot end that ensures:

Maximum consistency and repeatability in the different shot stages which guarantees uniform casting quality.
Increased reliability of the injection: the use of flexible pipes avoids breakages that might occur during high pressure peaks.
Easier access to parts of the injection system that requires maintenance, this ensures a LEAN maintenance process and increased machine uptime.

Efficiency all round

Rigid construction of the Closing Unit secures better closing of the die to reduce scrap rates and flash.

A quicker die change is made possible with the tie bars automatic removal option to allow more comfortable and LEAN die change.

Operator-friendly

The control system is tailored to your needs. It is based on a standard Siemens or Allen Bradley PLC with software specifically designed for die casting. Its user-friendly design makes it easy to operate and upgrade as it is made of standard control components that offer reliability and availability of supply.

5700t closing force for premium carmaker

TF5700: Not just a smart new look

Not just a Smart new look...for a Leaner machine

Because the new TF5700 comes fully digitally enabled, it doesn’t just look smart. It is Smarter. Primed for advanced use of data and ready to connect with your specific systems – and of course to our digital solutions – the TF5700 delivers much more than Massive closing forces in a Leaner shape...for Maximum benefit with Minimum footprint.

„Lightweight construction and electric vehicles are driving the demand for ever bigger castings – structural components and battery housings, for example. Die casting machine sizes have to keep up with that. The market’s responded very positively to it and we’re getting enquiries from around the world.” Marco Giegold, Area Sales Manager at Italpresse Gauss.

Find out more about our first TF5700 machine

Casting process in principle

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Technical data

Technical data for medium TF die casting machines

Machine sizes: TF 1000 - TF 2150

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Medium size cold chamber toggle free die casting machines

Cold Chamber	TF Series	TF 1000	TF 1350	TF 1650	TF 1850	TF 2150
Closing force	kN	9810	13243	16186	18148	21090
Injection force (with 0/25 bar backpressure)	kN	1015 / 892	1150 / 1011	1294 / 1137	1470 / 1298	1704 / 1505
Injection stroke	mm	740	740	800	900	1000
Platens dimensions	mm	1520 x 1520	1785 x 1785	1960 x 1960	2200 x 2200	2230 x 2260
Distance between tie-bars	mm	950 x 950	1050 x 1050	1150 x 1150	1300 x 1300	1350 x 1350
Min. /Max . die height	mm	550 / 1000	600 / 1040	700 / 1150	800 / 1210	900 / 1400
Max. moving platen stroke	mm	1300	1400	1500	1650	1800
Ejection force	kN	486	574	574	574	716
Central ejection stroke	mm	200	240	255	280	300
Max. surface area (with pressure on metal 40 MPa)	cm2	2450	3310	4040	4535	5270
Max. shot weight	kg	19	21.8	23.6	26.5	37.8
Motor rating	kW	55	2 x 37	2 x 37	2 x 55	2 x 55
Machine weight	t	48.5	67	96	116	144.5
Overall dimensions (length x width x height)	mm	9090 x 3460 x 3540	9225 x 4060 x 3750	9667 x 4320 x 4300	11120 x 4780 x 4690	11775 x 4930 x 4685

Subject to technical alterations

Technical data for large TF die casting machines

Machine sizes: TF 2500 - TF 5700

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Large size cold chamber toggle free die casting machines

Cold Chamber	TF Series	TF 2500	TF 2700	TF 3060	TF 3500	TF 4400	TF 5700
Closing force	kN	24525	26487	30019	34335	43164	56000
Injection force (with 0/25 bar backpressure)	kN	1704 / 1505	2135 / 1885	2135 / 1885	2818 / 2489	2818 / 2489	3320 / 3040
Injection stroke	mm	1000	1250	1250	1250	1500	1600
Platens dimensions	mm	2535 x 2535	2535 x 2535	2880 x 2880	3060 x 3060	3200 x 3200	3500 x 3500
Distance between tie-bars	mm	1550 x 1550	1550 x 1550	1700 x 1700	1780 x 1780	1850 x 1850	2000 x 2000
Min. /Max . die height	mm	900 / 1500	900 / 1800	1100 / 1650	1200 / 1800	1300 / 2000	1400 / 2400
Max. moving platen stroke	mm	2000	2450	2000	2100	2500	3300
Ejection force	kN	716	716	996	996	996	1196
Central ejection stroke	mm	300	300	325	350	400	400
Max. surface area (with pressure on metal 40 MPa)	cm2	6130	6620	7505	8585	10780	14000
Max. shot weight	kg	42.4	59.1	59.1	65.4	78.5	110
Motor rating	kW	2 x 75	2 x 90	2 x 110	2 x 110	2 x 160	3 x 110
Machine weight	t	167	171	216	240	296	350
Overall dimensions (length x width x height)	mm	12140 x 5000 x 4947	13611 x 5220 x 4910	14230 x 5400 x 5220	14780 x 5600 x 5830	16960 x 6000 x 5930	17700 x 6500 x 6300

Subject to technical alterations

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The following features are available as options:

ECO-FIT and ECO-FIT PLUS

Achieve energy savings of up to 50% with our energy efficient ECO-FIT solutions. ECO-FIT and ECO-FIT Plus can be integrated into the HPDC and GDC machines to regulate the hydraulic pumps to reduce energy consumption, reduce hydraulic fluid temperatures and reduce noise levels. Both solutions deliver instant benefits. In addition to lower energy consumption, they also include a reduction of the hydraulic fluid temperature and a lower noise level. Both ECO-FIT Mode and ECO-FIT Plus can be retrofitted on existing machines.

#PerfectFit - integrates perfectly with:

Westomat Classic

The closed, crucible-free Westomat Classic dosing furnace with advanced ProDos 3 controls achieves maximum dosing precision and superior melt qualities.

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