{"id":9069,"date":"2026-01-06T05:52:56","date_gmt":"2026-01-06T05:52:56","guid":{"rendered":"https:\/\/www.alcircle.com\/blog\/?p=8177"},"modified":"2026-02-11T13:54:51","modified_gmt":"2026-02-11T13:54:51","slug":"al-in-all-12-hubei-unveils-worlds-first-one%e2%80%91piece-large-aluminium-frame-for-byd-vehicles","status":"publish","type":"post","link":"https:\/\/www.alcircle.com\/blog\/al-in-all-12-hubei-unveils-worlds-first-one%e2%80%91piece-large-aluminium-frame-for-byd-vehicles","title":{"rendered":"AL in ALL #12 Hubei unveils world’s first one-piece large aluminium frame for BYD vehicles"},"content":{"rendered":"\n

Some innovations don\u2019t just improve a product, they rewrite the engineering playbook. That is exactly what Chinese automotive supplier Hubei Hantek Equipment Manufacturing Co., Ltd.<\/strong> has done by introducing the world\u2019s first one\u2011piece, low\u2011pressure\u2011cast, all\u2011aluminium large vehicle frame, now installed in BYD\u2019s premium SUV.<\/p>\n\n\n\n

A structural breakthrough in vehicle engineering<\/h2>\n\n\n\n

At the 2025 Yangtze River Industry and Technology Innovation Conference<\/strong> in Hubei on December 2, 2025, Hantek unveiled an aluminium frame that pushes material and casting limits. Covering 4.2 square meters with wall thicknesses from 4 mm to 50 mm, this frame achieves an unprecedented 12:1 thickness ratio, something no global automotive aluminium casting project had accomplished before.<\/p>\n\n\n

\n
\"\"<\/a><\/figure>\n<\/div>\n\n\n

Image credit: Manufacturing Today<\/em><\/p>\n\n\n\n

Traditional aluminium frames are assembled from dozens of welded or riveted parts, creating weak points and raising manufacturing costs. Hantek\u2019s single\u2011piece design eliminates these joints. The result: higher structural rigidity, fewer fatigue failures and improved crash performance, all while simplifying production. <\/a><\/p>\n\n\n\n

Solving tough casting challenges<\/h2>\n\n\n\n

This feat was not simple. Hantek spent years refining low\u2011pressure casting techniques for oversized thin\u2011walled components, fine\u2011tuning molten metal flow, controlling fill rates and managing solidification gradients across extreme thickness variations. These process innovations, supported by proprietary aluminium alloys and optimised heat\u2011treatment cycles, enable the frame to maintain high strength, toughness and fatigue resistance, critical for demanding automotive use. <\/a><\/p>\n\n\n\n

Industry officials highlighted this achievement as a major milestone in China\u2019s capabilities for large, complex aluminium structural components, with the potential to reshape how future electric SUVs and pickups are engineered. <\/a><\/p>\n\n\n\n

A showcase in a luxury electric SUV<\/h2>\n\n\n\n

The one\u2011piece frame is installed in the BYD Yangwang U8L<\/strong>, a luxury electric SUV launched in September 2025 and priced at around 1.28 million yuan (USD 181,200)<\/strong>. Built on BYD\u2019s advanced e4 platform, the U8L boasts a powerful hybrid and multi\u2011motor setup with a Blade battery, 880 kW output, multiple drive modes and executive\u2011class features. <\/a><\/p>\n\n\n\n

What this means for the aluminium value chain<\/h2>\n\n\n\n

This innovation goes beyond a single vehicle model. Hantek collaborates with other major OEMs such as Nio, FAW Hongqi and Dongfeng Lantu<\/strong>, meaning the impact of large one\u2011piece aluminium castings could spread widely across the electric vehicle market. As low\u2011pressure casting competition grows, manufacturers are increasingly applying these technologies to large body modules, subframes and EV battery tray areas where aluminium\u2019s strength, weight savings and design flexibility deliver real value. <\/a><\/p>\n\n\n\n

In an industry where lightweight structural performance and manufacturing efficiency are decisive factors, this breakthrough stands as a testament to the role of advanced aluminium engineering in next\u2011generation EV design.<\/p>\n\n\n\n

Source: Hubei introduces world\u2019s first one-piece large aluminium frame installed in BYD vehicles<\/mark><\/a><\/em><\/p>\n","protected":false},"excerpt":{"rendered":"

Some innovations don\u2019t just improve a product, they rewrite the engineering playbook. That is exactly what Chinese automotive supplier Hubei Hantek Equipment Manufacturing Co., Ltd. has done by introducing the world\u2019s first one\u2011piece, low\u2011pressure\u2011cast, all\u2011aluminium large vehicle frame, now installed in BYD\u2019s premium SUV. A structural breakthrough in vehicle engineering At the 2025 Yangtze River […]<\/p>\n","protected":false},"author":97,"featured_media":9156,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[309],"tags":[477,544,545,546,342,547,548],"class_list":{"0":"post-9069","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-end-user","8":"tag-alinall","9":"tag-byd-aluminium-frame","10":"tag-byd-yangwang-u8l","11":"tag-china-gigacasting-suppliers","12":"tag-ev","13":"tag-hubei-aluminium-casting-supplier","14":"tag-one-piece-aluminium-casting"},"yoast_head":"\nOne-piece aluminium frame for BYD EVs | Hubei casting<\/title>\n<meta name=\"description\" content=\"Hubei unveils the world\u2019s first one-piece aluminium vehicle frame for BYD. 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