German-Italian pair of engineers nominated for patent 'Oscars
They are Fiorenzo Dioni and Richard Oberle of the Idra Group. They have been selected by Epo (the European Patent Organisation) in the 'Industry' category for the European Inventor Award to be presented in July in Malta. They are responsible for the largest die-casting machine for moulding car components while reducing waste and energy use
3' min read
Key points
3' min read
The largest die-casting machine in the world to reduce waste and energy consumption by producing much larger car 'parts' with fewer components, applying the innovative patented regenerative injection system called 5S. It was invented by Fiorenzo Dioni and Richard Oberle, an Italian-German pair of engineers from the Idra Group, who were nominated as finalists in the 'Industry' category of the European Inventor Awards 2024 for their contribution to the automotive industry. Dioni and Oberle were chosen from over 550 nominees for this year's edition. A sort of patent 'Oscar', which the Epo (European Patent Office) awards each year to the most innovative productions of genius among those filed and protected in its Munich offices. This year, Dioni is the only Italian selected.
How the patent works
.The Giga Press is a press specifically designed to mould large, simple vehicle body parts in a simplified process. Compared to traditional methods that can require the assembly of up to 70 separate parts, the Giga Press produces two to three large parts that make up the entire body of a car, reducing the number of components, waste and energy consumption.
The production process involves melting the aluminium alloy with natural gas. The molten aluminium is injected into the mould using the 5S (Strong, Simple, Stable, Smooth and Sustainable) injection system. Next, the casting is removed, cooled and checked for defects with X-rays. The next step involves trimming the casting with a laser and drilling with a computer-controlled machine. The Giga Press incorporates a metal recycler that collects aluminium offcuts and scraps for reuse in the next casting cycle, significantly reducing material usage. According to the European Aluminium Industry Association, recycling aluminium saves around 95% energy and reduces greenhouse gas emissions. The latest Giga Press models reduce energy consumption by 54 per cent, according to company estimates.
The Hydra Group points out that the Giga Press has made it possible to reduce the costs of automotive factories by 40%. This is due to the simplification of production processes, the reduction of required parts, and the minimisation of transport costs.
"The big brands in the industry welcomed our idea because we created a new industrial solution just in time and without which they would have been in trouble,' said Fiorenzo Dioni. 'The heat engine is in decline and our solution looks to the future because it is not only innovative but also sustainable and green.
Candidates
.Born in Brescia in 1963 (where he still resides), Dioni is the head of engineering at Idra Group and has been working on the Giga Press project since 2016, developing modifications with energy efficiency impacts that have proved incredibly useful for the industry. Not only that. He also has a passion for writing and is the author of fiction books and fantasy stories, which he has published through publishing houses.
