Gigantic aluminium die-casting machines help carmakers save costs up to 40%

The use of giant aluminium die-casting machines, such as those made by Tesla supplier IDRA Group, can reduce manufacturing costs by up to 40 per cent by replacing around 60 welded components.

Massive casting equipment, commonly called Gigapresses, was invented by Tesla to produce single, enormous pieces of vehicle underbodies, expedite production, and lighten the workload of even robots. As a result, it has become the most profitable manufacturer of battery electric vehicles (BEVs).

Critics claim that the approach carries dangers to quality and adaptability because a single defect might jeopardise the integrity of an entire module and make troubleshooting more challenging.

However, as raw material costs rise and the industry struggles to maintain profit margins, automakers, including Toyota, General Motors, Hyundai, Volvo Cars, and Chinese electric vehicle startup Nio are looking to organisations like IDRA for assistance.

Riccardo Ferrario, the General Manager of IDRA, said, "The basic idea was to provide a technology that could simplify the car production process."

Battery packs currently make up 25 per cent-40 per cent of the total cost of BEVs. It would be best if you made the rest cost less.”

Ferrario added, “Automakers claim that by adopting aluminium casting machines, they can cut the average cost of their parts by 30 per cent and the investments needed to create the chassis, which is the second most expensive portion of a car after the engine. It's a way to make BEVs something for all pockets eventually."