At present, Tesla has equipped large-scale die-casting machines in four factories around the world (including the United States, China, Germany, and Australia). These machines can create aluminum alloy parts of various shapes and sizes in minutes, such as hoods, doors, bodywork, and more. Compared with the traditional method of splicing multiple parts together in the car manufacturing industry, the production method of Massive Single Piece Casting has the advantages of rapid production and low cost.
1. Application of integrated die-casting in new energy vehicles
A casting production expert in Germany said: "It is right that the California factory adopts the same die-casting production method as the Texas factory to manufacture chassis parts. This production method can further reduce the price of the Model Y model and also allow the factory to The production line is simpler and easier to manage." Perhaps, traditional car companies should consider whether to use this method to reduce costs and increase profits.
Tesla adopts an integrated die-casting method in the production process, combining multiple parts into a whole, thereby reducing the process and cost in the production process, and improving production efficiency and product quality. By using large die-casting machines, Tesla can not only reduce production costs but also improve production efficiency and product quality, thereby gaining higher market competitiveness.
2. The large die-casting machine reduces the area of the factory area by 30%, and the rear bottom plate is built in 90 seconds
Foreign media pointed out that large-scale die-casting machines often have considerable volume and weight. Coupled with supporting power supply and control devices, one die-casting machine may require a separate factory building, and a super-large factory building can often only Install a few large die-casting machines.
However, the advantages brought by large die-casting machines are also considerable. Through the Massive Single Piece Casting die-casting production method, large die-casting machines can independently complete the production of some large parts in a shorter time, the efficiency of the production line is higher, and the production system of the entire factory is simpler and easier to manage.
Take the rear floor of Model Y as an example, this part adopts the Massive Single Piece Casting process. This part of the Model 3 does not use a one-piece die-casting plate but is spliced into 70 different parts. That is to say, people may need to design 70 sets of molds first, and then set up supporting facilities such as fixtures and processing tools according to the molds. The production process also requires the cooperation of multiple pieces of equipment, and the time cost and economic costs are relatively high.
On Model Y, the rear floor, which may have been spliced from 70 parts, can now be formed by combining only two large castings. The production cost of Model Y’s single vehicle has been reduced by 20%, and the factory area has also been saved by about 30%. In the future, Tesla will further simplify the production process of this part and strive to make the die-casting machine work once to produce a complete rear floor.
Foreign media pointed out that Tesla's factories in California, Texas, Berlin, and Shanghai are equipped with large die-casting machines. Perhaps, traditional car companies should consider whether to use this method to reduce costs and increase profits.
3. Whether new energy vehicles use Massive Single Piece Casting, there are also different voices
According to Tesla's description, the Massive Single Piece Casting process does help simplify the body structure, reduce vehicle manufacturing costs, and also help make the production line simpler and easier to manage.
However, when the aluminum alloy parts on the car are damaged, the car owner often needs to spend a lot of money and time to repair the car. The front and rear floor panels of Model Y are made of Massive Single Piece Casting aluminum alloy panels. If there is any damage, the owner has to replace the entire floor panel, which will cost much more than replacing a small part.
Our company is a professional die-casting factory. We are equipped with large-scale die-casting equipment and testing machines that meet the needs of New Energy Vehicle Massive Single Piece Casting. If you have ideas and needs for integrated die-casting, please feel free to consult.