Why Tesla And Other EV Makers Are Betting Big On Gigacasting

Automakers are rushing to produce cheaper EVs and profitably. While the costs and challenges of improving batteries often hog the spotlight, automakers are also investing billions into new manufacturing methods that can change the way cars are made. One such method is gigacasting or megacasting - using high pressure molds to form molten aluminum into large parts. Electric car maker Tesla is credited with pioneering the method, but several rivals are making investments. CNBC spoke with experts including Volvo Cars' Chief Product and Strategy Officer, Erik Severinson, about the Swedish car maker’s plans in this area.

Chapters:
00:00 - 01:41 Title card - Why Tesla and other EV makers are betting big on gigacasting
01:49 Chapter 1 - A revolutionary process
05:26 Chapter 2 - The potential
08:41 Chapter 3 - Future outlook

Producer: Robert Ferris
Editor: Evan Lee Miller
Animation: Jason Reginato Christina Locopo
Senior Managing Producer: Tala Hadavi
Additional footage: BMW, Getty Images, Hyundai, Idra Group, Kia, Mercedes-Benz, Nissan, Rivian, Tesla, Toyota Motor Corporation, Volvo, Volkswagen

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Why Tesla And Other EV Makers Are Betting Big On Gigacasting

[evmike]

Creator failed to point out that one of the challenges of large castings is they need to be made without the need for heat treating. Heat treating a large casting leads to warping, i.e., the potato chip effect, no two are the same. With the cooperation of a SpaceX metallurgical engineer Tesla developed their own aluminum alloy for casting that does not require heat treating. Also, in addition to the reduction in parts, there is a significant reduction in the number of robots required for welding stamped parts together.

[PhongNguyen-nzkz]

This video fail to tell you that the scrap pieces can be reused as molten metal. It’s not all doom and gloom on the scraps.

[kemollen]

Weird that CNBC haven’t made this video the last 2-3 years because for Tesla this is news.

[ColinFox]

They didn't mention that the aluminum cast rejects can be re-melted and shot again. You cannot do the same thing with steel and aluminum stamping, since the factory uses rolls of sheet steel and aluminum and does not have the capability to create another roll of metal, whereas they DO have the ability to melt down aluminum and re-use it.

[joseluiz]

You guys are like 5 years late with this story.

[Shagwyre]

A positive Tesla video😲, oh my times have changed

[unofficialmedia]

When the vehicle crashes you are gigafu*ked😂

[richard]

I've never understood why enhancements like this are discussed only within the use case of EVs when they could theoretically be used for ICE vehicles as well.

[BadL_]

The short clip at 00:26 is how tesla is planning to produce their vehicles in the very near future. Instead of it being on a production line and slowly assembled as it goes down, Tesla wants to split each major piece of the car into its own production area. Once all the pieces are made, it goes to final assembly where the whole car is then put together like legos.

This increases how many employees can work at each station, and means that if there is a problem or delay, it doesn’t stop all the other parts from being made. The other stations can still keep on working

[rajumulinti]

Integrating the parts is very cost effective idea like, we do with plastic injection molding. Automotive companies need to identify cost effective Designs in terms of tooling/ material to produce cheaper cars. This is one of example, as we learned already traditional casting parts are have some manufacturing defects and high scrap rate.I believe tesla have already implemented some advancements to overcome such issues in this manufacturing which are not completely disclosed in this video. But one of the advantage with casting is recyclability, the scrap can be reused, where as stamped process scrap can’t directly reused.

[ProjectILT]

Can't wait for the 5 year late video in 2029 about how Tesla is betting big on autonomy and how everyone else is just starting to try and copy them

[mcarrusa]

This process gives-rise to the $40, 000 dent repair, we have seen in some vids (rivian being the most infamous one).

I don’t know if they’re using gigacasting, but the reason why the dent repair was $40, 000 is because, even for a fist sized dent next to the tailgate, they had to replace the full right side skin, bumper to bumper.

This required full disassembly of all systems on that side of the vehicle …and there were only like five shops in the US that could even do it.

The quote came back at $40, 000. Painless dent repair guy who did the video did it for about five.

It wasn’t factory-fresh, but 98% convincing. A decent trade off for $35k, or having your basically brand new truck totaled by a fist-sized dent.

[MikeEnsor]

Best explanation of the problem understandable by most people. Very well done

[saleesh]

The German automobile industry may experience a significant decline in sales.😅

[rikt]

so just a crack on that one piece the entire section is damaged

[jasehkhk]

one bumper bender and the whole car is totaled. I'll be staying away with any cars with gigacasting. only one benefit from this is the auto makers. Expect the insurance rates to doubled once this evolution is in full motion. How much cheaper the car needs to get to make consumer benefit from this?

[Cybernatural]

Tesla gigacasting uses a new alloy that has a lower defect rate.

Also many are finding repairing a casting isn't that difficult. Welding can work more often than people realise. Although replacing castings may be easier.

[hockeyfun]

The Model 3 does not use Gigacastings for either the front or the rear assembly. Only the Model Y and CyberTruck.

[cwemmow]

When the Chinese benchmark a car they go to a Tesla car, not a legacy auto makers car. Two companies they go to are Caresoft and Munro Associates who does COST ANALYSIS to the nuts and bolts of a car, that includes the cost of labor and assembly.

[JigilJigil]

Tesla has been using Gigacastings for a couple of years now and Germans are still busy arguing if it's a good choice or not.