In the world of cutting-edge innovation, Tesla is no stranger to pushing the boundaries of technology. Even their existing technologies are not immune to groundbreaking improvements. One such advancement that has been silently revolutionizing the way vehicles are produced is the ingenious “gigapress.”
This groundbreaking technology has already enabled substantial cost reductions in the construction of Tesla’s Model Y. The rear section of these vehicles has been manufactured in their Shanghai plant using the gigapress since 2020, resulting in a remarkable 40% reduction in production costs.
But Tesla has even bigger plans on the horizon. According to a recent report from Shanghai Securities News, the company is now set to take this technology to the next level by creating entire underbody parts of their cars in a single, seamless piece – a process referred to as “gigacasting.”
Gigacasting is achieved through a remarkable machine that expertly presses molten aluminum into a mold. After cooling and release, this process results in a fully constructed car part. What makes Tesla’s innovation even more impressive is the development of a unique aluminum alloy that eliminates the need for the conventional heat treatment process, making the final product stronger and more cost-effective, as reported by Reuters.
The impact of this revolutionary technique is not limited to Tesla alone. Other prominent electric car manufacturers, such as Xpeng and Zeekr, are closely monitoring these advancements and considering the adoption of gigacasting in their own production processes. Toyota is also following suit by incorporating gigacasting to fabricate components for a modular structure in their upcoming electric vehicles.
According to insider sources, Tesla’s “unboxed” manufacturing strategy, which includes gigacasting, could potentially accelerate car production significantly. This means that Tesla could build cars from the ground up in a mere 18 to 24 months, a fraction of the time it would take their competitors, who typically require three to four years for the same task. Terry Woychowski, the President of American engineering company Caresoft Global, emphasized that gigacasting, while challenging, has the potential to revolutionize automotive construction.
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In line with their broader vision, Tesla aims to introduce a small electric vehicle priced at around $25,000. Gigacasting plays a pivotal role in realizing this goal, as Tesla seeks to make electric cars more accessible to the masses.
The importance of affordable electric vehicles cannot be overstated. A recent Deloitte study, the 2023 Global Automotive Consumer study, revealed that 52% of respondents identified cost as the most significant barrier to purchasing an electric vehicle. Bringing an affordable EV to the market can help expedite the transition from conventional fossil fuel-powered vehicles to clean, zero-emission alternatives, ultimately benefiting the environment and our society as a whole.
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