Torsus, a Czech Republic headquartered manufacturer of some of the world’s toughest heavy-duty off-road vehicles, has expanded its Slovak engineering and production operations with the opening of a second manufacturing facility in Ilava.
The new site creates 100 jobs and adds the people, equipment and space required to increase production of the Terrastorm and Praetorian ranges. It also strengthens Torsus’ ability to develop and manufacture specialist vehicles for mining, energy, emergency response, construction, government and remote industrial operations.
Together with the company’s existing pre-assembly operation in Horné Srnie, Ilava gives Torsus a combined manufacturing footprint of 9,420m² and a Slovak production team of more than 150 people.
The expanded operation provides annual production capacity for up to 200 Terrastorm and 50 Praetorian vehicles, with multiple models and customer projects able to progress through production simultaneously.
TORSUS has completed more than 350 projects and supplied over 5,000 vehicles to customers in more than 20 countries across four continents.
Slovakia is one of Europe’s leading automotive manufacturing centres, supported by a highly skilled engineering workforce, an established supplier network and extensive vehicle-production expertise.
Its central European location also gives Torsus access to major international road, rail, port and logistics networks, supporting the delivery of vehicles, components and spare parts to customers worldwide.
The Ilava facility brings together digital engineering, prototyping, specialist metal fabrication, vehicle assembly, quality control and parts fulfilment within one coordinated operation.
At the centre of the facility is the Torsus Digital R&D Centre, where engineers develop vehicle systems, specialist conversions and customer-specific equipment.
Advanced CAD software, including SolidWorks and Plasticity, allows the team to create detailed three-dimensional models of components, assemblies and complete vehicle systems before production begins.
In-house 3D printing accelerates the development of customised parts, enclosures, interfaces and mounting systems. Engineers can move quickly from a digital concept to a physical prototype, assess it on the vehicle and make changes without waiting for conventional external tooling.
A dedicated prototyping area, separate vehicle lift and specialist engineering workstations allow development work to continue alongside regular vehicle production.
A major focus of Torsus’ engineering operation is its heavy-duty 4x4 HD system for specialist commercial vehicles with a gross vehicle weight of up to 5.5 tonnes.
The system combines low-range gearing with locking differentials, giving operators greater traction, torque control and low-speed manoeuvrability across steep gradients, mud, loose surfaces, cross-axle obstacles and broken terrain.
This configuration is not available as a standard Volkswagen or MAN solution for vehicles in this category. Torsus develops and integrates the system for applications where maintaining forward progress is critical.
The drivetrain is engineered alongside reinforced suspension, underbody protection, drivetrain breathers, electronics and customer equipment. Vehicle weight, axle loading, centre of gravity and suspension behaviour are assessed to ensure the completed vehicle remains stable and controllable under full-load off-road conditions.
The Ilava operation supports both of Torsus’ principal vehicle ranges.
Terrastorm is a highly adaptable heavy-duty 4x4 platform developed for passenger transport, emergency response, cargo, utility support, mobile workshops, medical units, cranes and expedition vehicles.
Praetorian is Torsus’ flagship heavy-duty 4x4 off-road bus, engineered to carry personnel and equipment across terrain beyond the reach of conventional buses.
Each vehicle is developed around its operating role, with passenger safety, equipment access, power supply, ventilation, water systems, weight distribution and structural integration considered throughout the engineering process.
In-house laser cutting and metal bending allow Torsus to manufacture structural parts, underbody protection, brackets and customised components with greater control over accuracy, quality and lead times.
Torsus structures its manufacturing processes in line with Volkswagen AG standards, covering incoming-part inspection, assembly procedures, documentation, traceability and final vehicle certification.
Vakhtang Dzhukashvili, Founder and CEO of Torsus, commented: “Slovakia gives Torsus access to exceptional automotive engineering expertise, a strong supplier network and an ideal location from which to serve customers around the world.
“The new Ilava facility gives our teams more space, greater production capacity and the tools to move faster from digital design to prototype and finished vehicle.
“Our customers operate in environments where traction, durability and reliability are essential. Expanding our engineering and manufacturing capabilities means we can deliver more Terrastorm and Praetorian vehicles, support increasingly specialised applications and maintain the quality expected from every Torsus.”
Torsus vehicles are supplied through the company’s international dealer network and supported by Volkswagen and MAN service centres around the world.
Each vehicle is supplied with a two-year global warranty and comprehensive aftersales support, with extended warranty options available in selected markets.