In the pursuit of reducing costs and increasing profitability for electric vehicles (EVs), automakers are exploring various innovative approaches. While advancements in battery technology often receive significant attention, substantial investments are being made in revolutionizing other aspects of vehicle manufacturing.
One notable method is mega casting, or gigacasting as Tesla refers to it. This technique involves die-casting—pouring molten aluminum into large molds to produce vehicle components. Although die-casting has been utilized for some time, Tesla, under the leadership of Elon Musk, has been recognized for advancing this process. According to Shea Burns, a partner at AlixPartners specializing in automotive manufacturing, Tesla’s adoption of this technology aims to enhance manufacturing efficiency and reduce vehicle weight.
Tesla has demonstrated the benefits of this method by streamlining the chassis of its vehicles. For instance, the early Model 3 chassis required over 70 parts for the front and rear sections, whereas the Model Y integrates these sections into a single part each. Musk has stated that this innovation leads to lighter, more cost-effective parts with improved noise, vibration, and harshness characteristics, and predicts that such manufacturing techniques will become standard in the industry.
Other major automakers, including Toyota, Ford, General Motors, Hyundai, Nissan, and Volvo, are also investing in similar technologies. Erik Severinson, Volvo’s Chief Product and Strategy Officer, highlights that reducing weight and complexity enhances vehicle range and production efficiency.
However, experts caution that megacasting faces technical challenges. Issues such as potential voids in the castings, higher scrap rates, and difficulties in repairing large cast parts remain concerns. Wolfram Volk, a professor at the Technical University of Munich, notes that large castings may be prone to deformation even in minor accidents, complicating repairs.
Despite these challenges, Tesla’s vice president of engineering, Lars Moravy, argues that repairing cast parts can be more cost-effective and efficient compared to stamped parts. Nevertheless, Tesla has recently scaled back plans to cast entire vehicle underbodies in one piece, suggesting potential technical limitations.
As the technology continues to evolve, its long-term viability and potential obstacles remain to be fully assessed.
