30 years of innovation with FICEP’s Direct Drive presses – from friction systems to Direct Drive screw solutions

The evolution of forging presses tells a story of innovation, transitioning from traditional friction presses to direct drive screw presses, a true leap forward that has revolutionized the industry.

In the past, friction presses relied on leather-based systems, which were prone to wear and environmental factors such as humidity and temperature, causing significant variability in the quality of the finished product.

These limitations made it difficult to ensure process repeatability, especially as forging materials became more advanced and required systems capable of delivering high forces with consistent precision. Additionally, the high number of components made maintenance operations complex.

The need for better process control and increased reliability led FICEP to introduce the first direct drive screw press in 1995, known as Direct Drive (DD), marking a breakthrough in forging technology. The first model, the DD68, delivered a net force of 85 kN.

In these machines, a brushless motor directly drives the screw, eliminating the complexity and inertia of traditional mechanical transmission systems. With highly precise software control, the screw’s rotation speed—and therefore the ram descent speed—can be adjusted with an accuracy of 0.5% on the delivered energy.

This technological solution provides numerous competitive advantages:

• Elimination of variability: by removing mechanical components subject to wear, the Direct Drive system ensures consistent process repeatability and greater precision in energy transfer, defining the deformation degree and accuracy of the forged part.

• Simplification and reliability: the simplified design, with fewer components, results in easier maintenance and increased structural robustness, making these presses particularly suitable for high-strength special alloy applications.

• Energy efficiency: the integration of the Kinetic Energy Recovery System (KERS) allows the recovery of energy normally lost during braking, leading to energy savings of up to 60% under certain conditions. Combined with advanced electronics provided by partners like Siemens, this makes the production cycle not only more cost-effective but also more sustainable.

• Integration with automation: the ability to integrate 6-axis and 4-axis robots allows for better control of critical aspects such as temperature and lubrication, ensuring that parts are always processed under the same operating conditions and significantly reducing waste.

Today, Direct Drive presses represent cutting-edge technology for numerous industrial sectors, including automotive, agricultural industry, earthmoving, aerospace, petrochemical, and medical sectors.
Their ability to handle innovative materials—such as titanium, special steels, duplex, and super-duplex alloys—with high precision and versatility makes these machines reliable partners for high-tech production.

In summary, the shift from friction presses to direct drive screw presses has overcome the limitations of traditional technology, offering integrated numerical control, superior reliability, energy efficiency, and simplified maintenance operations.

Even traditional hammers are now being replaced by DD presses, which offer significant advantages in flexibility, precision, and final product quality. This transformation has laid the foundation for more precise, repeatable, and sustainable production, capable of meeting the challenges of an ever-evolving market.

With 95 years of expertise in forging, FICEP stands as a complete partner for the global industry, offering an integrated technology range from bar cutting to hot forging presses, including fully automated forging lines with anthropomorphic robots.

The Research and Development department continuously analyzes market needs and introduces technological innovations, positioning FICEP as a driving force behind the industry’s most significant advancements. A prime example is the Direct Drive presses, which have been serving our customers for 30 years, now available in a range from 6,700 kN up to 100,000 kN for a maximum continuous force.