ILLIES KOREA introduces Giga Steel Roll Forming Machines to Sungwoo, Korea

For over a decade, the automotive industry has been exploring lightweight solutions, testing various materials to enhance efficiency. As the demand for weight reduction continues - while maintaining structural integrity in the event of an accident - Giga steel (Ultra-High Strength Steel, UHSS) has emerged as a key alternative, particularly in the E-mobility sector.

Giga steel is now being used for critical automotive safety components, including bumpers, crash boxes, and the main frames of EV battery cases, providing enhanced protection in collisions. European OEMs and major U.S. manufacturers have already adopted Giga steel for EV body structures and battery enclosures. However, processing this material presents significant challenges due to its exceptionally high tensile strength of 1.8 GPa, compared to conventional steel (400–800 MPa).

Recognizing this need, ILLIESpartnered with Sungwoo, a Tier 1 supplier for Hyundai Motors with operations across Europe, America, and Asia. Sungwoo specializes in bumper rails, body frames, and chassis components. When the company sought a solution for efficiently processing Giga steel, they faced difficulties achieving consistent, stable forming results with locally available solutions. To overcome these challenges, Sungwoo turned to ILLIES Korea for expertise.

After extensive research, ILLIES selected Dreistern GmbH & Co. KG, a renowned German specialist in Giga steel roll forming. Dreistern has a strong track record in Europe, North America, and Asia, offering high-precision, high-speed roll forming lines with cutting-edge innovations, such as laser welding and turnkey system integration. Their technology delivers superior machine availability and production speeds of up to 200 meters per minute, depending on the application.

Impressed by Dreistern’s advanced capabilities, Sungwoo placed orders for roll forming systems for their Mexican facility, which will supply components directly to GM’s Detroit factory. Looking ahead, Sungwoo anticipates that this technology will gain traction among automotive and E-mobility OEMs in Asia as well.