Spray Systems for Large Die Casting Machines
| Produkte, Technologie, Unternehmen
Giga and megacasting are reshaping die casting production. Larger die surfaces, extreme thermal loads and cycle times under ten seconds demand spray systems that can keep up at every scale.
The rise of gigacasting for structural automotive components creates demands that physically exceed conventional spray concepts. Die surfaces spanning several square meters, high cyclic thermal loads and short cycle times require spray systems that are precise, reproducible, and highly dynamic at the same time.
Wollin offers two coordinated system concepts for these requirements: robotic spray solutions with one, two or three coordinated ESR robots, and portal systems from the ESM8 series for maximum payload and reach.
2- or 3-robot spray solution
The flexible entry-level solution for large-surface spraying: two or three ESR robots work in coordination and together cover the entire mold surface. The modular design enables short changeover times when switching mold geometries.
Suitable for the new generation of large die casting machines in gigacasting.
Sufficient reach for large-format tooling and complex die geometries.
Designed for heavy mask spray tools and large-surface applications.
Configuration scalable to mold size and process requirements.
Integration into existing robot cells without major retrofitting.
Consistent coverage across the full die surface — cycle after cycle.
ESM8 portal systems
For applications requiring maximum payload and large strokes, Wollin offers three portal configurations from the ESM8 series. All variants are designed for die casting machines up to 9,000 t.
ESMT8 G
Linear telescopic sprayer. An economical solution for high payloads and short cycle times.
| ESMT8 G — Technical data | |
| DCM range | up to 9,000 t |
| Horizontal stroke | 3,200 mm (extendable) |
| Vertical stroke | 3,200 mm (extendable) |
| Spray circuits | 16 |
| Payload | 600 kg |
ESMT8 GM
Linear telescopic sprayer with additional spray tool traversing unit — for optimal coverage even at large mold widths.
| ESMT8 GM — Technical data | |
| DCM range | up to 9,000 t |
| Horizontal stroke | 3,200 mm |
| Vertical stroke | 3,200 mm |
| Spray tool stroke | 2 × 380 mm |
| Spray circuits | 16 |
| Payload | 2 × 300 kg |
ESM8 PGM
Portal with traversing, travel, and service axis. Vibration-decoupled from the die casting machine — with a separate service axis for easy maintenance during ongoing production.
| ESM8 PGM — Technical data | |
| DCM range | up to 9,000 t |
| Portal stroke | 3,500 mm |
| Horizontal stroke | 1,900 mm |
| Vertical stroke | 3,100 mm |
| Spray tool stroke | 2 × 380 mm |
| Spray circuits | 16 |
| Payload | 2 × 300 kg |
| Special feature | Vibration-decoupled, separate service axis |
Mask spray tools for complex geometries
For structural parts with complex geometries — battery housings, Shock Towers, floor structures — Wollin develops custom mask spray tools. They enable precise, geometry-matched spraying while minimizing release agent consumption and spray time.
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The combination of coordinated robot kinematics and geometry-specific mask spray tooling enables short spray times even for large, complex mold surfaces — without any compromise on reproducibility. |
Interested in a spray solution for your machine?
We are happy to advise you on the right system configuration — robotic solution or portal, for any machine size.