Tesla's groundbreaking Gigacasting 2.0 transforms car production

author: FutureCar Staff    

Tesla is making a technological breakthrough in the production of electric vehicles that could significantly reduce costs and revolutionize the manufacturing process, according to five sources familiar with the move. The company has already used "gigacasting" to mold the front and rear structures of its Model Y, cutting production costs and causing competitors to scramble to catch up. Now, Tesla is closing in on another innovation that would allow it to die cast nearly all of the complex underbody of an EV in one piece, rather than using around 400 parts in a conventional car. This innovation is a key part of Tesla's manufacturing strategy to produce cheaper EVs in large quantities while still turning a profit.

Terry Woychowski, the president of Caresoft Global, a US engineering company, said that if Tesla is able to gigacast most of the underbody of an EV, it would disrupt the industry and change the way cars are designed and manufactured. Tesla's new design and manufacturing techniques could also significantly reduce the time it takes to develop a car, with the ability to create a new model from the ground up in just 18 to 24 months, compared to the three to four years it takes most rivals.

Tesla is considering using a single large frame for its small EV, combining the front and rear sections with the middle underbody where the battery is housed. This approach could help Tesla achieve its goal of launching a $25,000 EV by the middle of the decade. The decision on whether to die cast the platform in one piece is expected to be made soon. The design and manufacturing process for such large castings has traditionally been expensive and risky, but Tesla has found a way to overcome these challenges.

The breakthrough Tesla has made involves using 3D printing and industrial sand to create the giant molds for the large castings. This allows for the incorporation of hollow subframes with internal ribs, reducing weight and improving crashworthiness. Automakers have been hesitant to cast ever-bigger structures due to the high costs and risks involved. However, Tesla has worked with design and casting specialists to develop a process using 3D printing and sand casting that is more cost-effective and flexible. This process allows for rapid prototyping and significantly reduces the time and cost of the design validation cycle.

To cast subframes with hollows as part of the gigacasting process, Tesla plans to use solid sand cores printed by 3D printers. The sand is then removed after the casting is complete, leaving the desired voids. Tesla has also formulated special alloys and fine-tuned the cooling process to ensure that the castings meet their criteria for crashworthiness and other attributes. Once the prototype mold is approved, Tesla can invest in a final metal mold for mass production.

Tesla's upcoming small cars, designed for personal use and as robotaxis, have a simpler underbody design, making them ideal candidates for casting the EV platform in one piece. However, Tesla still needs to decide on the type of gigapress to use and this will determine the complexity of the car frame. To produce such large body parts quickly, Tesla will need bigger gigapresses with clamping power of 16,000 tons or more. These presses may require larger factory buildings. One challenge with high clamping power presses is that they cannot house the 3D printed sand cores needed for hollow subframes. Tesla may overcome this by using a different type of press that allows for the slow injection of molten alloy, producing higher quality castings and accommodating the sand cores.

FutureCar Staff