Gigacasting: Die-Casting Innovation, Under Pressure

ConstructionResourcesManufacturingTransportationInnovationHealthcare
Written By Mike Iwankiw

Exploring Gigacasting’s Journey from Automotive Breakthrough to Potential Cross-Industry Disruptor

What if a single innovation could (quite literally) reshape entire industries?

Gigacasting, initially crafted for Tesla's EVs, might just be that breakthrough – capable of transforming not only automotive manufacturing but also sectors like construction, healthcare, and transportation. From simplifying production and reducing costs to driving sustainability, gigacasting embodies the potential to redefine modern die-casting and manufacturing.

Gigacasting…

  • Offers transformative potential for industrial die-casting across sectors like modular construction, heavy equipment, aerospace, and healthcare, by simplifying processes, strengthening components, and reducing complexity. As the innovation is fine-tuned (reparability, etc.) it will be poised to change the die-cast industry.

  • Is projected to grow from $109 million in 2024 to $711 million by 2029, with a CAGR of 45.5%, driving efficiency and reducing emissions in the $112 billion die-casting market and supporting over 10 million vehicles by 2030.

  • Requires major investments and adaptations, focused on scalability. Tesla’s shift from single-piece aspirations to three-piece reality underscores the need for flexible strategies to overcome technical and economic hurdles.

  • BONUS: For the most up-to-date news in Gigacasting, check out Luca Greco on X.

Pressure: It Busts Pipes and Fuels Innovation

Gigacasting, pioneered by Tesla and its partners, is redefining automotive manufacturing by consolidating hundreds of parts into a few large castings. This innovation simplifies production, reduces costs, and enhances sustainability. Beyond automotive, gigacasting holds transformative potential across sectors like construction, mining, transportation, manufacturing, and healthcare.

In our previous article, we explored how this advanced approach to die-casting could reduce manufacturing costs and time, setting a new industry benchmark. Gigacasting is more than a manufacturing technique – it exemplifies how forward-thinking strategies can disrupt entire sectors. By casting large sections of vehicles in single or simplified pieces, Tesla has streamlined production while enhancing vehicle performance. This process increases structural rigidity and reduces weight, offering a significant advantage for electric vehicles where weight reduction boosts range and efficiency.

Gigacasting Timeline. Describing the innovations beginnings and potential growth. Source: KPIT Technologies

Gigacasting Timeline. Source: KPIT Technologies.

Industries worldwide are beginning to take notice of these benefits and Gigacasting, particularly when coupled with Automation & Machine Learning, is primed to impact the entire die-casting industry:

Construction (Modular Homes):

  • Giga Press technology can support modular construction by producing large structural components like wall panels, roof trusses, and framing sections. For instance, a Giga Press could create entire wall panels with embedded channels for electrical and plumbing, significantly reducing on-site labor. 

Mining & Natural Resources:

  • In mining, where robust equipment is essential, Giga Presses can manufacture durable components such as frames, gearboxes, and engine parts. While casting has been a mainstay of the industry, as far back as the industrial revolution, the sector’s juggernauts are poised to take advantage of gigacasting’s benefits as well as the autonomous technology that companies like Tesla and other car manufacturers are implementing both in production and application. 

Transportation (Rail & Aviation):

  • Large-scale casting in transportation enables production of high-strength parts like train chassis and bogie frames, replacing multiple parts with a single casting. 

Manufacturing (Heavy Equipment & Robotics):

  • For industrial machinery, gigacasting could be applied to produce large frames and body components in fewer steps, enhancing production efficiency. Robotic and automation equipment frames, base plates, and support structures could benefit from larger and more rigid parts for stability.

Healthcare:

  • Die-casting could produce large, single-piece frames for medical devices, such as MRI and X-ray machines, reducing vibration and noise. Hospital bed frames, which require both strength and mobility, could be die-cast in a single piece, enhancing ergonomics and safety.

Giga Press, an EV innovation, is poised to impact the entire die-casting industry.

Full Court (Giga)Press:
How EV Manufacturing is Fueling the Evolution of Die-Casting

Tesla’s introduction of gigacasting in the Model Y was transformative, replacing 171 parts, eliminating 1,600 welds, and removing 300 robots from the assembly line.

This innovation dramatically reduced manufacturing costs and streamlined production processes (Irish News). Additionally, Gigacasting has shifted material demands in automotive manufacturing, with aluminum castings gaining prominence. This has intensified competition between materials, with steelmakers developing advanced high-strength solutions to challenge aluminum’s role. Steel proponents argue that while gigacasting can reduce assembly line expenses, part costs could rise unless offset by manufacturing savings. 

Tesla production plant, with robots working assembly line.

With Gigacasting, Tesla was able to reduce robots used in production.

Despite these advances, scaling gigacasting has posed challenges. Reports indicated that Tesla would scale back on single-piece gigacasting, opting instead to refine its three-piece approach – casting front and rear sections with an aluminum and steel midsection frame for batteries. According to Reuters, Tesla decided to step back from its plan to implement next-generation gigacasting to produce a car's underbody in a single piece. This adjustment was influenced by challenges such as declining sales, shrinking profit margins, and increased competition in the electric vehicle market. Nevertheless, Tesla emphasized that gigacasting remains a vital cost-reduction tool requiring significant investment and refinement.

A recent towing test by WhistlinDiesel, comparing the Cybertruck to the Ford F-150, demonstrated both the strengths and limitations of gigacastings. Under extreme stress, the Cybertruck’s rear casting failed, showcasing Tesla’s design strategy of engineering gigacastings to break at specific points, acting as crumple zones. This controlled break approach simplifies repairs by allowing only the damaged section to be replaced, an essential consideration for industries that require efficiency aligned with maintenance practicality.

Large single-piece castings raise questions about reparability. For example, Chinese automaker Chery Auto recently achieved gigacasting an entire vehicle underbody. And, while innovative, this approach raised concerns about repair costs, as damage to a single section, such as a strut tower, might necessitate replacing the entire underbody rather than the damaged part alone. This highlights a critical balance manufacturers must strike between production efficiency and practical, consumer-friendly design.

Peer Pressure for the Greater Good:
Gigacasting Sustainability

In addition to boosting efficiency, gigacasting addresses with sustainability goals by reducing material use and optimizing energy consumption.

The focus on reducing emissions through optimized material use, energy efficiency, and recyclability of aluminum demonstrates gigacasting’s critical role in creating a more sustainable automotive future.

The streamlined gigacasting process significantly cuts energy requirements and lowers the overall carbon footprint, which is particularly advantageous for electric vehicles that require lighter weight to maximize range and efficiency. Sustainability is a particularly strong benefit of gigacasting when using recycled aluminum. Producing recycled aluminum emits only about 3-5% of the CO₂ compared to primary aluminum production, making it both cost-effective and environmentally friendly (LightMetalAge). This not only reduces the carbon footprint of manufacturing but also encourages a circular economy in the automotive industry. Furthermore, gigacasting's ability to minimize waste and reduce the need for multiple smaller parts helps conserve raw materials and energy, contributing further to sustainability goals.

Die-casting technology, such as gigacasting, is increasingly being recognized as an effective solution for producing more sustainable automotive components. The combination of larger single-piece castings with optimized use of recycled materials exemplifies how innovations in manufacturing can align with broader sustainability initiatives in the automotive sector. By driving down emissions, reducing energy usage, and conserving materials, gigacasting offers a pathway towards greener production practices. This is a key reason why Tesla and other automakers see immense potential in scaling gigacasting technology as part of their sustainable production strategies.

Navigating the Pressures of
Gigacasting’s Evolution

Tesla’s early foray into gigacasting faced technical, logistic, and economic challenges.

Beyond the obvious defects from material inconsistencies and weak points, which are inherent risks when scaling large aluminum castings, the gigacasting innovation came with many challenges. Uniform solidification and structural integrity in single-piece castings require precise material engineering and advanced design techniques to minimize defects like porosity and shrinkage. These issues, coupled with the high costs for gigacasting machines and setup, made initial savings from labor reduction slower than anticipated, leading Tesla to adjust its approach.

As of November 2024, gigacasting remains central to Tesla’s production strategy, albeit with adaptations. Tesla’s decision to retain a three-piece casting approach – including front and rear castings with a midsection frame – demonstrates how addressing technical challenges while preserving the benefits of reduced complexity and cost savings can strike a balance between innovation and practicality.

Initially, reparability was another significant hurdle for gigacast components, as damage often required complete replacements. However, advancements in repair methodologies, such as using structural adhesives, rivets, and backing plates, now allow technicians to repair specific sections without replacing the entire casting. These techniques have reduced costs and complexity, enhancing the practicality and sustainability of gigacasting for automotive manufacturing and broader applications in Industry 4.0.

The global die-casting market is projected to grow from $82.86 billion in 2024 to $112.14 billion by 2029 (CAGR of 6.24%), fueled by the rising demand for lightweight, high-strength components that improve fuel efficiency and reduce emissions. Within this growth, the gigacasting market is set to expand significantly, with Mordor Intelligence estimating a leap from $109.13 million in 2024 to $711.61 million by 2029 — a staggering CAGR of 45.5%. This rapid growth reflects gigacasting’s increasing adoption in electric vehicles (EVs), where lightweight components are critical to offset heavy battery packs. Forbes adds to this perspective, projecting gigacasted EV to reach $2.6 billion by 2030, with over 10 million vehicles featuring large die-cast parts by then. Together, these figures underscore the transformative role of gigacasting in enhancing efficiency and reducing emissions.

Despite its potential, challenges persist. Gigacasting’s scalability depends on substantial investments in specialized equipment and infrastructure, as the required high-pressure die-casting machines necessitate significant space and resources. Furthermore, supply chain adaptations are needed to support the large-scale production of single-piece components. These constraints underscore the importance of flexible strategies and ongoing innovation to unlock gigacasting’s full potential.

Pressing The Issue:
Adopting and Adapting Innovation

Tesla's experience with gigacasting underscores the importance of adaptability in manufacturing.

The company's strategic shift reflects a commitment to refining gigacasting in response to technical and financial challenges. This flexibility is essential for the successful scaling of advanced manufacturing processes.

Other automakers are also embracing gigacasting as part of their EV production strategies:

  • Nissan plans to implement gigacasting by 2027, with goals of reducing expenses by 30% and vehicle weight by 20%. This strategy involves using 6,000-ton presses to create rear underbody sections for their EVs, consolidating up to 100 parts into large aluminum castings. 

  • Toyota is leveraging gigacasting technology, with plans to install a 9,000-ton gigacasting machine at its Aichi prefecture facility – one of the largest in Japan. This initiative aims to reduce EV production costs, with the upcoming Lexus LF-ZC slated to incorporate gigacast parts in its front and rear body segments. By employing gigacasting, Toyota could consolidate the rear section’s 86 components into a single cast part, marking a significant milestone in their production approach.

  • Hyundai announced plans to invest $730 million to build a “hypercasting” plant in Ulsan, South Korea. Slated to begin mass-production in 2026, the “hypercasting” method uses a press that employs a force from 6,000 to 9,000 tons.

The adoption of gigacasting by these major automakers highlights a significant shift in the automotive industry towards more efficient and sustainable manufacturing processes. This trend not only enhances competitiveness in the EV market but also signals a broader transformation in the die-casting industry, with potential applications extending beyond automotive manufacturing.

As gigacasting technology continues to evolve, its principles of reducing complexity, improving efficiency, and promoting sustainability are poised to influence various sectors. Industries such as aerospace, construction, and consumer electronics may find innovative applications for gigacasting, leading to advancements in product design and manufacturing methodologies.

The ongoing developments in gigacasting underscore its potential to drive a significant leap in the die-casting industry as a whole, paving the way for a new era of manufacturing excellence.

Giga Press:
Casting the Future

Gigacasting’s influence continues to expand as more companies recognize its value.

Similar to innovations like EV batteries, gigacasting has required iterative development to reach industry-wide adoption. Tesla’s strategic decision to use a three-piece approach balances gigacasting’s benefits with scalability considerations. Scaling gigacasting will require significant investment and careful cost-benefit analysis. Initial investments in gigapress equipment and production line modifications must be offset by savings in labor and materials over time.

The implications extend beyond automotive. Gigacasting in construction could enable prefabricated components, reducing labor and build time, while in mining, casting with fewer materials could streamline production and support sustainability. However, manufacturers must weigh the efficiency gains against consumer considerations. Chery Auto’s experience in gigacasting an entire vehicle underbody highlights potential trade-offs, as repair costs and long-term expenses become factors.

Looking ahead, gigacasting’s scalability will likely influence multiple industries. The future is forged under pressure, and gigacasting exemplifies the potential to transform that pressure into progress.

How can gigacasting principles apply across industries? Where else could gigacasting drive efficiency and innovation?

Sources & Additional Reading:

Additional Reading

Mike Iwankiw
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