books. Mahmoud Amin |
Tesla has reportedly made a technological breakthrough when it comes to the so-called “Gigacasting” process that would allow it to cast almost all of the electric car’s complex underside in one piece.
According to five people familiar with the plans, Tesla has combined a series of innovations to enable one-piece die casting. If the information is accurate, this is a major achievement because building such a large frame using traditional methods typically requires assembling hundreds of separate components.
This could change the way Tesla makes electric cars and contribute decisively to cutting production costs in half.
Knowing how to achieve this is at the core of Tesla’s manufacturing strategy that Elon Musk unveiled in March, which is key to his plan to build tens of millions of cheaper electric cars over the next 10 years, the sources said.
Tesla’s new design and manufacturing techniques could allow the company to develop a car from the ground up in 18 to 24 months, compared with 3 to 4 years for most competitors, two of the insiders said.
The breakthrough revolves around how gantry molds for such a large part are designed and tested for mass production, and how the molds can integrate hollow subframes with internal ribs to save weight and enhance endurance.
The innovations, which are being developed by design specialists in the UK, Germany, Japan and the US, include 3D printing and artificial sand. More specifically, Tesla has turned to companies that make test molds from artificial sand using 3D printers.
The sources said that Musk’s vision from the beginning was to find a way to cast the bottom of the car in one piece, despite the risks, and this is what the company is working on.
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2023-09-15 15:05:55
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