Gigacasting: A Game-Changer for Automotive Manufacturing

author: FutureCar Staff    

Gigacasting is gaining momentum in the automotive industry, offering various advantages such as improved car body stiffness, reduced manufacturing cost, and decreased assembly time and cost. Toyota recently unveiled a prototype of its gigacasting equipment, capable of producing a third of a vehicle chassis in just three minutes. This die-casting process is expected to significantly cut manufacturing lead time and production processes, bringing Toyota closer to its goal of producing 3.5 million electric vehicles per year by 2030.

Tesla, a pioneer in large-scale die presses, is reportedly working on an innovation that would enable the die casting of the entire complex underbody of an electric vehicle in one piece. This development highlights the growing interest in casting technologies in the automotive industry.

Other automotive companies, such as Volvo Car Corp, Hyundai, Ford, and Aisin, have also embraced gigacasting technologies. Volvo Car Corp has invested €855m ($909m) into its Torslanda plant for the development of megacasting technologies. The company has chosen Swiss supplier Bühler to provide die-casting cells for the plant, which will be used to produce the floor structure of its electric vehicles by 2025.

The installation of two enormous gigapresses in Volvo Cars' Torslanda factory in Gothenburg further demonstrates the adoption of gigacasting technologies. These giant presses can apply 8400 tons of pressure to press car parts and will significantly contribute to Volvo's production capabilities.

Experts in the field, such as Professor Shouxun Ji from Brunel University London, believe that the shift towards integrated casting structures is inevitable in the coming years. Gigacasting offers advantages such as improved car body stiffness, reduced manufacturing cost, and decreased assembly time and cost. Rapid innovation has led to the development of high-pressure die-casting machines with significantly higher clamping forces.

However, challenges remain in controlling the thin wall structure of high-pressure die casting and manufacturing the machines themselves. Digital twins and simulation innovations are expected to accelerate progress in gigacasting.

Professor Wolfram Volk from the Technical University of Munich raises concerns about the complexity of aluminium die casting and its impact on scrap rates. He also notes that gigacasting is not necessarily a lightweight solution compared to cold-forming processes or sheet-metal shells. However, gigacasting offers new possibilities for rethinking car body construction, especially for electric vehicles.

Die casting's potential to outpace traditional metal sheet fabrication remains uncertain. However, market indicators suggest a growing interest among electric vehicle manufacturers in streamlining production, reducing manufacturing lead times, and achieving ambitious sales targets.

Overall, gigacasting developments are significant for the automotive industry, with various companies investing in and adopting this technology to enhance their manufacturing processes and meet the demands of the electric vehicle market.

FutureCar Staff