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An escalating quantity of EV producers are displaying curiosity in integrating big aluminum castings, or mega-castings, into their vehicle structures, in spite of “many uncertainties about restore capacity, everyday living cycle and growing older,” according to a new whitepaper from investigation agency Ducker.

Between the authors’ conclusions is that, for the reason that these big castings are “not of a mother nature to be straightened or even changed,” even a small accident could lead to a auto becoming declared a whole loss.

“Cars with these elements are … stiffer, easier, but also extra disposable, especially considering the fact that the ageing of these enormous casting elements is not still regarded,” authors Bertrand Rakoto and Leonard Ling notice In the whitepaper, “2022 Mega-Casting Developments for Automotive Manufacturers.”

Rakoto, Senior Engagement Supervisor – Worldwide Automotive Apply Chief, and Ling, Senior Analyst – Automotive Know-how Manager, observe that Mercedes-Benz, Volvo, and Volkswagen are between the OEMs subsequent Tesla’s direct in the use of mega-castings, in spite of the industry’s restricted working experience with the technological know-how.

Mercedes-Benz is “aiming for optimum price tag reduction and excess weight reduction” on its EQXX, a very low-quantity vehicle unveiled as a concept in the course of the very last Consumer Electronics Exhibit. “The car or truck is a technological physical exercise as Mercedes-Benz aims not only for decrease production charges, but also for pounds reduction (which mega-casting will make possible) main to a much better administration of energy usage to raise variety,” the whitepaper states.

Volvo introduced in February that it will be investing the equal of just more than $1 billion in its Torslanda factory to deliver automobiles that use giant aluminum castings. The OEM’s target, the whitepaper notes, is “to lower the bodyweight of cars, to strengthen the use of interior area, and to be capable to build a number of cars able of utilizing the same modules primarily based on the exact same physique-in-white things (mega-castings).”

In asserting its expenditure, the OEM reported mega-casting “creates a number of gains in terms of sustainability, cost and auto efficiency through the car’s life span, and Volvo Vehicles is a single of the initially car or truck makers to invest in this procedure.”

Volkswagen, which is mounting a problem to Tesla in the EV segment, intends to look at the use of mega-castings as component of its new Project Trinity, aiming to speed up production by way of “ramped-up automation” and the replacement of dozens of components with solitary-piece aluminum castings.

“Tesla suggests it can currently churn out a Model Y in 10 several hours at its new Giga Berlin-Brandenburg manufacturing facility in Gruenheide around the German capital, whereas it can acquire Volkswagen 3 occasions as lengthy to make its ID.3 electric automobile,” Reuters claimed.

Meanwhile, two Chinese EV startups, Nio and Xpeng, have dedicated to mega-castings by purchasing injection molding devices capable of 12,000 tons of pressure from IDRA (LK Equipment), the whitepaper says.

“The adoption of these mega-castings by makers other than Tesla are perplexing at this position,” the authors create. “To establish a definitive idea, quantity boosts, technological enhancements, and the initial customer feedback on large-mileage vehicles will be required. Even so, with certainty the sudden enthusiasm of premium producers for these alternatives tends to confirm that the economic equation and the profitability of electric powered motor vehicles are considerably from getting fixed.”

For Tesla, which put mega-casting into quantity generation on the Product Y in January 2021, the appeal of the process lies in reduced output charges. “Elon Musk stated this alternative eliminates 300 robots from the assembly line on Munro Live (YouTube). Mega-castings allow for to strengthen profitability by cutting down assembly time, length of the assembly line,” the whitepaper suggests.

“In phrases of reparability, the casting element is not of a character to be straightened or even changed. If it bends or breaks, the car will be a whole reduction. Nevertheless, this is unlikely to sluggish Tesla down in its approach as the manufacturer is looking at a new Giga-casting portion for the front of the foreseeable future Product 3 and Design Y,” as properly as a cast tray for the battery pack, the authors say.

This illustration from Tesla’s Design Y Collision Mend Treatments Guide delivers tips for restoring the Cast Front Less than Overall body. No repairs are authorized in the areas marked purple.

Because “the casting is not of a character to be straightened or even changed,” breakage will lead a auto to be categorized as a overall decline, the whitepaper claims. “The lack and charge of sections, as nicely as the beneath-ordinary capacity for repair, are good reasons more than enough for a insignificant fender-bender to switch a Tesla into a wreck in the eyes of insurers.”

Musk enthused about the course of action in a January 2021 tweet: “With our giant casting devices, we are pretty much trying to make total-measurement autos in the similar way that toy cars and trucks are built.

In response to a problem from Repairer Pushed News, the authors reported the use of the engineering is also new to draw trusted and exact crash information about the existing result of mega-castings on promises.

Only Tesla is applying the technological know-how, and its lack of an aftermarket areas policy “leads to bigger whole reduction verdicts after a crash,” they mentioned. “Therefore, even with figures, it would be tricky to attribute the character of a complete decline just to the Mega castings. If it exists, these types of info could be offered from insurance policy organizations and would necessitate a qualitative analysis to distinguish the good reasons behind a full decline selection.”

They extra that aluminum marketplace foundries that participate in the mega-casting provide chain, this sort of as Rio Tinto, are acquiring new alloys to enable greater repairability for mega-castings, such as welding properties for long run repairs.

Rakoto and Ling solid doubt on the effectiveness of die-casting as an assembly of resolution. For the reason that dies have to be designed to enable molten aluminum to arrive at the much finishes of elements devoid of turbulent circulation, they can not incorporate slim-wall style and design in locations exactly where significant strength and stiffness are not demanded.

For that explanation, cast aluminum parts have to have a minimum amount thickness of 2 to 3 millimeters, vs . .7 millimeters for sheet metal.

The whitepaper notes that Mercedes-Benz is operating on that difficulty, with a Bionicast procedure to decrease surplus content in those regions exactly where better energy is not needed, when Volvo expects a 15% excess weight conserving about steel as a result of design and style optimization.

More, whilst the set-up time and the scrap level (45% at Tesla in 2021) “are normally highlighted with much more value than with stamping elements,” the process necessitates far more adjustments. “Confirmed by suppliers, the delays Tesla has experienced in Berlin and Austin are not only administrative or financial, but also technical,” the authors say.


In spite of the considerations, mega-casting does present guarantee in some locations. Materials utilization can be increased, as effectively as the use of scrap aluminum. Volvo states that 100% of its aluminum will be used, as opposed to 55% of stamped metal components, and that 50 percent of the aluminum can be a secondary alloy, promising a CO2 emissions reduction of 35% or much more.

Rakoto and Ling say that the “limited experience” with the use of mega-castings leaves many fears unanswered, and go away OEMs “innovating by demo and mistake.”

“With cost-reduction being the conclude-recreation for Mega-casting technological innovation, the sudden enthusiasm of high quality producers for these methods tends to show that the economic equation and the profitability of electrical automobiles are much from being resolved,” they conclude.

Extra data

Ducker: Mega-casting tendencies for automotive makers

Volvo Automobiles to devote SEK 10bn in Torslanda plant for upcoming technology absolutely electric powered vehicle creation and trucks-to-invest-sek-10bn-in-torslanda-plant-for-subsequent-technology-absolutely-electric-vehicle-generation-1


Featured graphic: A mega-casting integrated into the entire body in white of a long term Volvo EV. (Provided by Volvo)

A Tesla Product Y, appropriate, uses 2 aluminum mega-castings in position of the 171 parts in a Tesla Model 3. (Supplied by Ducker)

Video clip offered by Volvo.

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By Tara