Toyota Motor has said that it will adopt a technology Tesla pioneering so-called “Gigacasting” as part of the Japanese automaker’s strategy to improve the performance – and reduce costs – of the future. tram (tram).
Toyota is not alone in following Tesla’s breakthrough.
Here’s a look at Gigacasting and how innovation is forcing automakers to scramble to match Tesla:
What is gigacasting?
Giga Press is an aluminum die-casting machine adopted by Tesla at its factories in the US, China and Germany. House-sized machines can produce much larger aluminum parts than anything previously used in car manufacturing.
The “giga” in the name is a nod to Tesla’s convention of calling its factories “Gigafactories”. Other automakers have referred to them as “super presses,” which may also refer to machines that are smaller but still massive.
During operation, the press injects 80 kilograms (176 pounds) or more of molten aluminum into a die so that it is formed into a part, released, and then cooled rapidly.
Tesla has developed an aluminum alloy that allows it to bypass the traditional heat treatment process used to increase the strength of the casting part.
What is the reward?
Typically, more than a hundred individually stamped metal parts have been welded together to form the bodywork.
Fewer parts, lower costs and simplified production lines have contributed to Tesla’s industry-leading profit per car, analysts say.
For Tesla, the use of a single component at the rear of the Model Y — its best-selling model — allows it to cut related costs by 40%, the company said.
inside 3 . sampleBy using a single piece from the front and rear of the vehicle, Tesla was able to remove 600 robot from assembly, Elon Musk said.
It can also cut the vehicle’s weight — an important consideration for electric vehicles when battery Packages alone can weigh more than 1,500 pounds. And it has the ability to reduce waste and greenhouse effect emissions from a tree.
Toyota says it hopes that the use of die-cast aluminum will remove dozens of sheet metal parts from the assembly process and reduce waste.
Who makes these machines?
Tesla sources its presses from Italy-based IDRA, which has been a unit of China’s LK Industries since 2008.
IDRA and LK competitors include the Buhler Group in Europe, Ube and Shibaura Machine in Japanand Yizumi and Haiti in China.
An analysis by AlixPartners shows that the global aluminum casting market was worth nearly $73 billion last year and is expected to reach $126 billion by 2032.
Who is chasing it?
Besides Toyota, common engine, hyundai Motor and its affiliates of China Geely — Volvo car, The North Star And Zeekr — are using technology or planning for it.
Zeekr has started using giant aluminum die-casting molds for a multi-purpose van it makes for sale in China and says it will introduce the technology to other models.
Volvo said last year it would invest more than $900 million to upgrade its plant near Gothenburg, Sweden, to include megapress technology.
Caught what?
Cost is one.
Tesla records most of its sales with just two models: the Model 3 and Model Y. Strong sales on just two platforms make it easier to invest in new manufacturing technology. Other EV startups have that advantage, too.
For established automakers with more complex product lines and depreciated factory machinery, the decision to invest tens of millions of dollars in new foundry technology, analysts said. could be a more difficult decision.
Cars with molded body parts can also be more difficult or more expensive Repair after an accident. That can add to the operating costs of electric vehicles.
Already Insurers are adding Teslas and other electric vehicles have a low range if the battery fails because there is usually no way to repair it even if the battery pack is slightly damaged.
