en.Wedoany.com Reported - Torsus, the Czech heavy-duty off-road vehicle manufacturer, has opened its second manufacturing facility in Ilava, Slovakia, to expand its engineering and production operations. The new plant adds 100 jobs and expands the personnel, equipment, and space needed to produce the Terrastorm and Praetorian model lines, while enhancing Torsus's capability to develop specialized vehicles for mining, energy, emergency response, construction, government, and remote industrial operations.

Together with the existing pre-assembly plant in Horné Srnie, the Ilava facility brings Torsus's total manufacturing area to 9,420 square meters, with a Slovak production team of over 150 people. The expanded facility can produce up to 200 Terrastorm and 50 Praetorian vehicles per year, while simultaneously advancing multiple vehicle models and customer projects.

Torsus has completed over 350 projects to date, delivering more than 5,000 vehicles to customers in over 20 countries across four continents. As one of Europe's leading automotive manufacturing hubs, Slovakia offers highly skilled engineering talent, an established supplier network, and extensive vehicle manufacturing experience. Its Central European location 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 integrates digital engineering, prototyping, specialist metalworking, vehicle assembly, quality control, and parts supply into a coordinated operational whole. At the facility's core is the Torsus Digital R&D Center, where engineers develop vehicle systems, specialist conversion solutions, and customer-specific equipment. Advanced CAD software, including SolidWorks and Plasticity, enables the team to create detailed 3D models of parts, assemblies, and complete vehicle systems before production begins; in-house 3D printing accelerates the development of custom parts, housings, interfaces, and mounting systems, allowing engineers to move quickly from digital concepts to physical prototypes for evaluation and modification on vehicles without waiting for traditional external tooling. A dedicated prototyping area, independent vehicle lifts, and specialist engineering workstations enable development work to proceed alongside regular vehicle production.

A key focus of Torsus's engineering operations is the heavy-duty 4x4 HD system for specialized commercial vehicles with a gross mass of up to 5.5 tons. This system combines low-range gearing with differential locks, providing operators with enhanced traction, torque control, and low-speed maneuverability for steep slopes, mud, loose surfaces, axle-crossing obstacles, and rugged terrain. This configuration is not a standard solution offered by Volkswagen or MAN for such vehicles; Torsus has developed and integrated the system for applications where maintaining continuous vehicle progress is critical. The drivetrain is co-engineered with reinforced suspension, underbody protection, driveline breathers, electronics, and customer equipment, while vehicle weight, axle loads, center of gravity, and suspension performance are assessed to ensure the complete vehicle remains stable and controllable under loaded off-road conditions.

The Ilava facility supports both of Torsus's core model lines. The Terrastorm is a highly adaptable heavy-duty 4x4 platform suited to passenger transport, emergency response, cargo, utility support, mobile workshops, medical units, cranes, and expedition vehicles; the Praetorian is Torsus's flagship heavy-duty 4x4 off-road bus, designed to carry personnel and equipment over terrain where conventional buses cannot operate. Each model is developed around its operational role, with engineering processes addressing passenger safety, equipment access, power supply, ventilation, water systems, weight distribution, and structural integration. In-house laser cutting and metal bending capabilities enable Torsus to manufacture structural components, underbody guards, brackets, and custom parts with greater control over precision, quality, and lead times.

Torsus builds its manufacturing processes to Volkswagen AG standards, covering incoming inspection, assembly procedures, documentation, traceability, and final vehicle certification. Vakhtang Dzhukashvili, founder and CEO of Torsus, stated that Slovakia brings Torsus exceptional automotive engineering expertise, a strong supplier network, and an ideal location for serving global customers; the new plant provides the team with greater space, increased production capacity, and tools for accelerated iteration from digital design to prototypes and finished vehicles. Torsus vehicles are sold through the company's international dealer network and supported by global Volkswagen and MAN service centers, with every vehicle backed by a two-year worldwide warranty and comprehensive after-sales support, with extended warranty options available in select markets.