Toyota CEO REVEALS Why Tesla Giga Casting Machines

Toyota CEO REVEALS Why Tesla Giga Casting Machines

Toyota Motor announced this week that it will use a Tesla-pioneered technology called "gigacasting" as part of a plan to increase the efficiency and decrease the cost of future electric vehicles (EVs).

Toyota is not the only company imitating Tesla's innovation. But what’s the reason for this new trend?

A new fashion trend has recently begun to gain traction. The giga-casting trend was started by Tesla and is also known as "mega-castings" by some OEMs. These massive cast structural elements can combine a variety of parts into a single, extremely large casting. This may affect not only how cars are made and how aluminum is used generally, but it may also change how much castings, sheets, and extrusions are used in light vehicles. To put it another way, it might promote new growth for castings while possibly inhibiting the growth of sheets and extrusions.

Tesla has incorporated the gigapress aluminum die-casting machine in its US, Chinese, and German factories. The home-sized machines can create aluminum components that are much larger than anything previously used in the production of vehicles.

The word "giga" in the name is a reference to Tesla's practice of referring to its factories as "gigafactories". They are now referred to as "megapresses" by other automakers, a term that can also be used to describe smaller but still enormous machines.

When the press is in use, it feeds an 80 kg or more shot of molten aluminum into a mold where it is shaped into a part, released, and then quickly cooled.

Tesla has created an aluminum alloy that also enables it to forego the standard heat-treating procedure used to boost the strength of the cast component.

Numerous studies, particularly those from Ducker-Carlisle, have demonstrated that the amount of aluminum used in light vehicles has been rising steadily over the years, surpassing 500 lbs (227 kg) per light vehicle in North America and 396 lbs (180 kg) per vehicle in Europe. Castings have traditionally been the most common product form, but sheet and extrusion applications have seen the fastest growth rates in recent years and will continue to do so in the future. The primary motivation for using aluminum has always been lightness.

The trend of aluminum's growth has only been sustained by the quickening electrification of vehicles, which has also altered the product mix. While hybrid vehicles typically have smaller engines and battery electric vehicles (BEVs) don't use internal combustion engines (ICEs), castings have historically been the most common product form and have primarily been used in the powertrain of ICE vehicles (primarily using secondary A380 or 319 alloys). The growth of aluminum has now moved to the car body and chassis, as well as the battery trays and electric drive components for electric vehicles. Today, the majority of these components are made from sheet and extruded materials, with only a small portion from castings, which are frequently structural and are therefore made using more advanced techniques and cleaner aluminum alloys (either primarily from clean scrap or secondary).

this time, numerous other automakers have made the decision to take the same route and have invested in giga-presses, including Volvo and its EV brand Polestar. Volvo plans to create a number of vehicle models that can utilize the same mega-casting for their body-in-white (BIW) components. Even mounting points for parts like suspension arms and electric motors will be integrated into the castings.

Mercedes-Benz, Volkswagen, Toyota, General Motors, Hyundai, and the Chinese electric vehicle start-ups Nio and Xpeng are other notable automakers that are openly known to be following this trend (or plan to)5.

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[luislongoria]

It seems castings will become the norm on par with vacuum formed FRP and carbon applications. As for Right to Repair, stamped sheets may still be needed to facilitate the unit body repair process which is far from the death knell to the collision repair industry. In fact, if the history of collision repair is any indicator, body filler and adhesives will continue to be the most widely used repair strategy for cracks in cast unit body parts

[jgarbo]

Giga Casting is not a "fashion". It's an obvious development in making car parts. Why bolt and rivet 50 small parts together when you make one simple unit --perfect? It's 2024!

[abelwoo]

Good for manufacturing but not consumer

[CrenorZ]

the video does not even come close to what your talking about

[jorgerobles]

At last the Legacy OEM's Leadership are starting to realize that Tesla has the answer to their EV Production woes, one of them being the Giga Press. But some of the problems mentioned here about the variable thickness that parts of a Giga- casting may have, have already been addressed by Tesla and are no longer valid, if the process is made in the same fashion as Tesla, and that is attested by the thousands of Tesla Model Ys being already produced. Each unit has two giga castings and Sandy Munro has said are perfectly aligned and processed. Another point that is senseless is the one that giga castings can not be repaired in case of damage. If there is damage to the vehicle that also damages the giga casting, that vehicle had suffered extreme damage and would be considered total loss and its occupants must possible are dead, so no need to repair.