Tesla Eyes Manufacturing Breakthrough With Gigacasting Innovation

Tesla Inc. TSLA is reportedly nearing a manufacturing breakthrough that could cut costs and boost the production efficiency of its vehicles.

The Verge reported that Tesla’s new production process will enable it to die-cast the entire vehicle underbody as a single piece, unlike traditional techniques which involve constructing about 400 separate parts.

Known as “gigacasting,” this approach, which Tesla already uses to an extent in building its Model Y SUV, is considered highly efficient and cost-effective. Now, Tesla is reportedly refining this technique even further.

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The updated method involves a mold-making process using 3D printing and industrial sand, enabling easy alterations, even when scaled up to the size of a vehicle. Despite challenges with the aluminum alloys used in casting, specialists were able to alter the alloy formula and fine-tune cooling and heat treatment processes to make it viable.

With this innovation, Tesla could cast a complete underbody in a single piece, replacing the traditional method of welding pieces together. This method requires larger “gigapresses,” indicating the need for more space in Tesla’s production facilities.

The new casting technique aligns with CEO Elon Musk’s previously announced “unboxed” production process. This process could streamline car building, starting with a single-piece cast, painting only the necessary parts, and assembling the rest in one step.

As part of Tesla’s ongoing aim to reduce manufacturing costs, this breakthrough could have a significant impact on the company’s bottom line. The new process is anticipated to be used on Tesla’s long-awaited $25,000 electric car.

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