Driven by Tesla's integrated die casting process, Chinese die casting technology has become a globally recognized hot topic. By combining multiple automotive components into one, this innovation simplifies production processes, increases efficiency, reduces manufacturing costs and enhances the rigidity of automotive parts. This technological breakthrough has brought significant changes to the automotive manufacturing industry.
Traditional Automotive Manufacturing Processes
Traditional automotive manufacturing processes can be broken into four stages: stamping, welding, painting and assembly. The manufacturing process of car bodies has always relied mainly on stamping and robotic welding. The process of welding the white car body in particular is the most complex, requiring at least 300 large industrial robots for multi-station continuous welding. Traditional car manufacturers tend to be conservative and reluctant to take risks, as this mature process has been used for decades.
The Role of Integrated Die Casting
Currently, the issue of range anxiety in electric vehicles has not been completely resolved. The technology for new sodium-ion batteries and solid-state batteries is still immature. To achieve long-range capabilities, the number of battery modules needs to be increased, which would significantly increase the weight of the car and reduce its range. Therefore, we need to improve the manufacturing process to reduce the weight of the vehicle.
In 2020, Tesla announced plans to adopt integrated die casting to produce the rear underbody of the Model Y. This method replaces the original 79 parts with just 1-2 large die-cast components. The number of robotic weld points is reduced from around 700-800 to an astonishing 50, and the manufacturing time is cut down from the traditional 1-2 hours to just 3-5 minutes. Additionally, the overall weight of the car is reduced by 30%, and manufacturing costs are lowered by 40%.
Advantages of Integrated Die Casting
The key aspect of integrated die casting is that it replaces the stamping and robotic welding stages with a single large die casting machine, thus driving a revolution in car body manufacturing processes.
Currently, the die casting machines used in the field of new energy vehicles are mainly cold chamber die casting machines. These machines produce various shaped castings by installing different die molds. The working principle involves pouring molten aluminum alloy into the shot chamber, then using an injection piston to rapidly push the molten aluminum alloy into the mold cavity. The mold's cooling system quickly solidifies the aluminum alloy parts, and once the mold opens, the final solid metal casting is obtained. This process is similar to giving an injection: initially advancing slowly, then quickly pushing to form the mold.
Compared to the over 300 robots required for a white car body welding line, die casting machines take up significantly less floor space. As integrated die casting technology becomes more widely adopted and gradually replaces welding robots, large tonnage die casting machines will become the core equipment in the automotive manufacturing field.
Auto Parts Will Be More Accessible
With the help of integrated die casting, automakers can obtain better automotive parts more quickly and conveniently. China has extensive experience in manufacturing metal parts. Regarding automotive parts, they can produce perfect components through processes such as stamping and die casting, supplying them to automakers worldwide.
We believe that in the future, after the widespread adoption of integrated die casting, new energy vehicles will dominate the roads, contributing further to the resolution of global environmental issues.
Image courtesy of the author.
Interested in reading more articles like this? Subscribe to ISA Interchange and receive weekly emails with links to our latest interviews, news, thought leadership, tips and more from the automation industry.
