JLR - An introduction to Irish Pressings - Automotive sector

Experts in the design and manufacturing of tooling, metal stamped components,
precision machining, welded assemblies, projection welding, and prototyping.

About us

• Irish Pressings Ltd. design and manufacture press tools, metal pressed components,
prototypes and welded assemblies for a range of sectors – most notably the
automotive industry.

• Formed in 2005 by the Ward Brothers – qualified toolmakers with over 30 years
industry experience.

• Located in Co. Donegal, Ireland - a strategic Gateway to Europe and the UK.
• Over 70 highly-skilled employees.
• Highly efficient automated production processes.
• Exporting across Europe and beyond.
• Certified Quality Assurance – ISO 9001 and IATF 16949.

Management Experience

Irish Pressings owners – Brendan and Declan Ward – have extensive industry experience between them:
• 30 years combined experience with Kirchhoff Automotive
• 7 years experience developing steering system components with NSK Steering.
• 22 Years experience in manufacturing of automotive components.
• Fulltime Consulting Design Engineer for the Ford Focus
• Consulting Engineer for the GM in development of production parts for Zafira, Vectra and Astra.
• Development of bumper systems, rear seat-assemblies, chassis, crash testing and energy-absorption systems

and other complex components.
• Working on production of parts on 1600 ton presses (press bed size 6 metres) with fully automated transfer line.
• Development and production of rear seat sub frames and bumper assemblies using high strength steel
• Project managing installation of robot cells containing 14 robots working in tandem.
• Process Engineering – Optimising and setting targets for machines/operators, designing and controlling process

flow, production planning and capacity for forecasts.

Irish Pressings – Connectivity

Irish Pressings is only 15 minutes
from Donegal Airport providing direct

flights to Dublin and Glasgow with
onward connections to all major

global destinations.

Belfast, Cork, Dublin and Rosslare
Ports provide daily sea-access to the

UK and mainland Europe.

Irish Pressings – Weekly deliveries to UK

Our Client base

Irish Pressings services its UK customers with a weekly delivery using our own Volvo FH Articulated
Truck and 40ft trailer, complete with full GPS tracking to ensure efficient delivery scheduling

OurICrilsihePnrtebssainsges - A local company, trading globally

Our clients

• Irish Pressings supply at Tier 1 and Tier 2 level to automotive customers across the UK, Europe and beyond.
• We supply tooling and/or components directly to Honda (UK), Benteler International AG, DURA Automotive, Gedia Automotive

Group, Kirchhoff Automotive, Magna International Autolaunch, NSK Steering Systems amongst others.
• Our end-customers in the automotive industry include Honda, Jaguar Land Rover, Aston Martin, Volkswagen, Opel, Ford, Bentley,

Audi and BMW.
• We are proud to have supplied components to the 2019 World Car of the Year, the Jaguar I-PACE.
• Irish Pressings was awarded a Honda Supplier Contribution Award in 2017.

Irish Pressings and JLR

Irish Pressings supplies 2 parts to the Jaguar IPACE

Irish Pressings supplies 5 parts to the Range Rover

Irish Pressings and JLR

Irish Pressings and JLR

Irish Pressings supplies 3 parts to the Jaguar XF

Irish Pressings supplies 5 parts to the Range Rover Sport

Irish Pressings and JLR

Irish Pressings and JLR

Irish Pressings supplies 2 parts to the Jaguar F-Pace

Irish Pressings supplies 3 parts to Jaguar XE

Irish Pressings and JLR

Irish Pressings and JLR

Irish Pressings supplies 3 parts to the Range Rover Velar

Irish Pressings supply 5 parts to the Range Rover Sport

Irish Pressings supplies 2 parts to the Jaguar F-Type

Irish Pressings and JLR

Irish Pressings and Aston Martin

Irish Pressings will supply 33 parts to the new Aston Martin DBX Crossover

Note – above is a “concept” image of DBX Crossover. Final car design and spec not yet released

Irish Pressings supplies 20 parts to the BMW i8

Irish Pressings and BMW

Irish Pressings supplies 17 parts to the Honda Civic

Irish Pressings and Honda

Irish Pressings and Honda

Irish Pressings supplies 9 parts to the Honda Civic Type-R

FR

Our Services • At Irish Pressings, we offer:
• design, feasibility, prototyping and testing;
• Innovation, research & development;
• In-house design and manufacture of tooling; and
• Metal pressing and production/manufacturing.

• Our standard business practice is to work with customers
through all stages of their project allowing the highest level of
design, quality and cost-control.

Design & FR
Simulation
• Simulation is a vital part of product development
• We utilise Dynaform simulation software
• In our 3D Design Department, we use the latest VERO VISI (CAD-CAM):
• Prototypes manufactured for pre-production analysis and testing.

Tooling FR

• Full in-house tool design, manufacture, assembly and try out.

• Ability to produce and hold spare parts.

• Full control of project timing and costs.

• Tooling capabilities supported by:
• flame cutting; wire erosion; 2D and 3D Machining; waterjet;
vacuum furnace; milling machines; and assembly stations.

• High and low volume batch production FR

• Development of prototypes and small batch orders without major tooling

costs

• Press size with a range of Beds up to 4m

• Stamping material in a range of grades and thicknesses

• Single stage and multi-stage progression tooling

Metal Stamping • Single stage and multi-stage manual tooling

• We also have the capacity to offer welded assemblies to our customers.

Stamping capabilities FR

Press Machinery

Quantity Machine Make Tonnage Type Handling Slide Area (mm) Bed Area (mm) Shut Height - Max (mm) Shut Height - Min (mm)

1 Press Sanki 800 Manual Hydraulic 3500x2000 3500x2000 2000 200

2 Press Seyi 400 Transfer Hydraulic 4000x1500 4000x1500 1000 400

1 Press Krupp 400 Progression Mechanical 2500x1400 2500x1400 600 400

1 Press Weingarten 400 Progression Mechanical 1800x1600 1800x1600 600 400

1 Press ALT-250 250 Progression Mechanical 2500x1200 2500x1200 500 450

1 Press Bliss 250 Progression Mechanical 1830x1070 1830x915 480 330

2 Press Bliss 150 Progression Mechanical 1830x1070 1830x915 480 330

3 Press VSS 250 Manual Mechanical 800x475 1100x740 360 280

1 Press Grigg 100 Manual Hydraulic 800x475 1100x740 360 280

1 Press Han Oul Press 60 Manual Mechanical 480x400 840x500 370 300

Machining FR• At Irish Pressings we have a range of Machining services available for use

including:
• 2D and 3D CNC Machines;
• Wire Electrical Discharge Machine (EDM);
• waterjet cutting machine; and
• gas-flame cutting machine.

• Working to tight-tolerances, we offer a top of the range service with a fast
turnaround time and all aspects of the work is carried out in-house by our
highly skilled team of operators and programmers.

Welding FR• We offer a variety of welding services - including projection welding,

welded assemblies and weld-testing - to our customers.

• All assemblies undergo various quality inspections to ensure that
the welding process itself is fully monitored and the requirements of
our customers are met.

• Robotic welding cells allow for consistency, efficiency and ensures
that the highest of quality are maintained.

Macro FR• As with all stages of the Irish Pressings production process, providing
weld-testing
assurance about the quality of our welding services is an essential aspect of
the comprehensive service that we offer.

• The in-house weld-testing process involves three core phases of preparation,
inspection and measurement using a digital microscope.

• Through the testing process we capture, analyse and measure macro samples
of MIG and Spot Welds in addition to plug-weld analysis.

• The output of the testing process is a final test report for in-house traceability
or to provide customer with required quality assurance.

Research, FR
Development
& Innovation • Innovation is a key feature of the Irish Pressings service-offering.

• At Irish Pressings, we evaluate customer requests, undertake R&D to
identify innovative solutions and cross-pollinate ideas between our
industry-experts and customers.

• We specialise in the development of solutions to overcome
technological uncertainties in a variety of engineering industries.

• Experience in the delivery of technological advancement to “traditional”
products.

• Available for funded collaborative research projects with industry
partners or academic institutions.

• As part of our 3-phase expansion plan (2019-2023) we propose to
develop a dedicated R&D Facility and Innovation Hub to stimulate our
R&D and creative capabilities regarding new products, materials,
working processes, etc.

Quality FR• Quality assurance is key to the continued success of Irish Pressings.
Management
• We employ Coordinate Measuring Machines (CMM) and the Equator
gauging system to ensure that quality standards are being met.

• We place a very high value on our quality standards and work towards
exceeding the expectations of our customers every time in relation to
their quality requirements.

• Irish Pressings are proudly certified to ISO TS16949:2009 and
ISO9001:2008 quality standards. This external accreditation validates
the quality management process that prevails within Irish Pressings.

Irish Pressings – Quality Control throughout our manufacturing process

• Design & Feasibility • Automation FR
• LS Dynaform
• Autoform • Robotic Assembly Cells
• CAD/CAM – VeroVisi
• Robotic Resistance Welders
• Tooling Manufacture
Our Machinery • Laser Cutting • Quality
& Equipment • Waterjet Cutting • Nikon LM1500 CMM
• Drill Sparking • Renishaw Equator Measurement
• Wire EDMs M/C
• Grinding Machines • Aberlink CMM
• CNC Machining Centres
• High-Speed Machines • Testing
• Force Testing
• Production • Cyclidic Testing
• Press sizes from 60t-800t • Weld Macro Testing
• Hydraulic and Mechanical • Material inspection (hardness,
presses tensile, grain structure)
• Progression and Transfer
• Logistics
• Volvo FH Articulated Truck – 40ft
with trailer

Current Projects • All door inner components FR

Large UK-based OEM • 23 Tools in total FRONT DOOR INNER WAIST PANEL LH/RH
• 5 Draw Tools MATERIAL-AC600-T4
- All door inner components • 4 Progression Tools
• 9 Transfer forming tools FRONT DOOR OUTER WAIST PANEL LH/RH
• 5 Trim & Pierce tools MATERIAL-AC600-T4
• 3 Tools with in-press nut clinching
• 1 welded assembly REAR DOOR INNER WAIST PANEL LH/RH
• CNC Machining of Extrusions MATERIAL-AC600-T4
• 6 & 5 Series Aluminium
REAR DOOR OUTER WAIST PANEL LH/RH
MATERIAL-AC600-T4

REAR-DOOR-LWR-HINGE-REINFLH/RH
MATERIAL-AC600-T4

• Carrying out detailed feasibility FR
• Costings for stamped parts & welded assemblies
Future Projects • Process layouts work flow
• Process layouts for Robotic Weld Cells
Large UK-based OEM • 27 components in assembly
• 13 different pressed parts
• 38 MiG Welds
• 52 spot/projection Welds
• 6 Weld nuts

Irish Pressings
3-phase expansion (2019 – 2023)

8 15 19 28 22

2019 2020 2021 2022 2023

Refurbishment of Comer building Development of Units 16-18-19

Phase 1 Purchase of Phase 2 New dedicated Demolish Unit 18 and build a
Units 16 and 18 Innovation Hub and R&D facility Phase 3 state-of-the-art manufacturing facility

between Units16-18-19

Phase 2 Purchase of New state-of-the-art Develop a new assembly line
Comer building Phase 2 tooling facility with additional capacity at Snáth Comer
Phase 3

Phase 2 Installation of new 800 ton
press to future-proof our
car component stamping operations

Phase 2 New Logistics and Dispatch
Centre

• Fáisc Miotail Éireann’s is aware that it needs to move now in order to be at the forefront of the industry transition towards Electric Vehicles, Hybrid, etc.
• To facilitate this, our proposed development plan is essential to allow for additional capacity, new innovation, enhanced tooling and pressing capabilities and a

more efficient manufacturing and logistics operation.

Innovative. Award-winning. Quality.

Contact us

+353 74 95 60810
[email protected]
www.irishpressings.com
www.linkedin.com/company/irishpressingsltd
www.instagram.com/irishpressingsltd/
www.twitter.com/IrishPressings (@irishpressings)
www.facebook.com/irishpressings/
www.vimeo.com/irishpressings