It is reported that a major breakthrough, a major breakthrough in Tesla's integrated die-casting! It may only take 18 months to develop a new car. With this breakthrough, Tesla can die-cast almost all the complex underbody parts of electric vehicles into a single piece. A car can be developed from scratch within 18 to 24 months.
Today, let's take a look at why integrated die-casting is so popular? It has been followed up by major car companies. What industrial chains are driven by this technology?
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According to calculations by CITIC Securities, the global penetration rate of integrated casting is expected to reach 30% by 2030. It is conservatively estimated that the value of bicycle accessories is expected to reach 10,000 yuan, and the industry space will grow from 2.2 billion yuan in 2022 to 246 billion yuan in 2030. , the compound growth rate reached an astonishing 80%.
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Why is integrated die casting so popular?
In fact, since Tesla proposed integrated die-casting technology in 2019, it has pioneered the industry of large-scale high-pressure casting. Subsequently, new energy automobile manufacturers such as Weilai, Gaohe, and Geely have followed suit. Integrated die-casting is a general trend and has promoted Popularization and promotion of large-scale integrated automobile structural parts.
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Integrated die-casting replaces traditional stamping and welding process
Compared with traditional automobile manufacturing, automobile integrated die-casting has advantages in many aspects such as manufacturing cost, production efficiency, labor cost, material recycling, etc., and is expected to subvert the traditional automobile manufacturing process. Compared with the four links of stamping, welding, painting and final assembly of the traditional automobile manufacturing process, integrated die-casting combines the stamping and welding links, simplifying the body manufacturing process.
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The industrial chain behind "integrated die-casting"
Integrated die-casting is a new process technology. There are new requirements and explorations in the chain for large-scale die-casting equipment, heat-free materials, die-casting parts process molds, vehicle demands and verification, etc., and cooperative research and development between upstream and downstream has become more important.
Among them, the upstream of the integrated die-casting industry chain includes die-casting machines, heat-free aluminum, magnesium alloy materials and molds. Upstream material, equipment and mold suppliers need to deploy heat-treatable aluminum alloy materials, ultra-large die-casting machines (above 6000T) and corresponding ultra-large integrated molds.
The midstream is an aluminum alloy die-casting factory, which needs to actively cooperate with upstream suppliers to equip the process of integrated die-casting production lines, accumulate sufficient experience, and continuously improve and improve to improve the yield rate of die-casting parts.
The downstream is the OEM. With the promotion of the Tier 0.5 cooperation model, more and more OEMs will have both midstream and downstream status, opening up the integrated die-casting industry chain and sharing more industry dividends.
The four major technical barriers of materials, equipment, molds and processes will be broken through layer by layer to jointly promote the development of integrated die-casting.
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Upstream: die casting machine
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Large die-casting machines are the basis for integrated die-casting of automobiles. Generally speaking, the clamping force of the die-casting machine required for integrated die-casting is above 6000T. Currently, the global companies that can produce 6000T die-casting machines include the overseas Idra Group (a wholly-owned subsidiary of Lijin Technology) and the Swiss Brown Group. Domestic Lijin Technology, Haitian Metal and Yizumi. Larger tonnage die-casting machines mean that the size and structure of die-casting parts can be further improved. Currently, Tesla, Lijin Technology, Guangdong Hongtu, Haitian Metal and other companies are developing die-casting machines with a capacity of more than 12,000T. In September 2022, Lijin Technology and Guangdong Hongtu released a 12000T ultra-large intelligent die-casting unit. This is the world's largest tonnage die-casting machine to date and is expected to help integrate vehicle-level die-casting parts.
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Mold is the core tool of integrated die-casting and has high barriers. Mold is a tool for forcing metal or non-metal forming. It can be divided into forming part, pouring system, mold base part, overflow system, temperature control system and other parts. It is an indispensable process equipment in industrial production. The mold produced The parts have the characteristics of high efficiency, high consistency, low energy consumption and high precision/complexity. The difficulty of mold making lies in mold design and raw material selection. Large-scale integrated die-casting requires high precision of molds, which increases the difficulty of mold making. Generally, die-casting manufacturers do not have the design capabilities for large-scale die-casting molds and rely on external procurement to meet demand. At present, my country's large-scale die-casting mold manufacturers mainly include Guangzhou Cavity, Ningbo Zhenzhi, Ningbo Savinda, Wencan Xiongbang, Heli Technology and Chongqing Guangcheng Mold, and the famous German mold company Schaeffler Mold Group also built factories in Zhejiang.
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Heat treatment-free alloy materials can improve the yield rate of integrated die-casting, thereby reducing costs. The heat treatment of aluminum alloys is divided into ingot homogenization annealing, recovery recrystallization annealing, solution (quenching) heat treatment, aging and deformation heat treatment. Traditional aluminum alloys need to improve the strength, plasticity, toughness, corrosion resistance and fatigue of aluminum alloys through heat treatment. comprehensive performance. Integrated die-casting of large-scale aluminum alloy parts requires high precision. The heat treatment process can easily cause dimensional deformation and surface defects of automobile parts. Although the correction process can improve certain dimensional accuracy, it will reduce the yield rate and lead to a sharp rise in costs. Therefore Heat-free aluminum alloy materials are the key to large-scale integrated die-cast structural parts. Foreign heat-treatable aluminum alloy material manufacturers mainly include Alcoa, Germany's Reinfeld and Tesla. Domestic manufacturers are actively researching and developing. At present, Lizhong Group, Shanghai Jiaotong University, Guangdong Hongtu, and Hubei Xinjinyang have successfully developed it.
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Midstream: Die-casting plant
Midstream die-casting manufacturers have deployed integrated die-casting, with Wencan, Hongtu and Tuopu leading the way. Midstream die-casting manufacturers such as Wencan Co., Ltd., Guangdong Hongtu, Tuopu Group, and Xusheng Co., Ltd. respectively purchase large die-casting machines. Among them, Wencan Co., Ltd., Guangdong Hongtu, and Topu Group have first-mover advantages in terms of experience accumulation and order acquisition. The three of them compete with Automobile companies established cooperation and began trial production of integrated die-casting parts.
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Downstream: car companies
There are two business models for integrated die-casting. One is the self-development model: the OEM directly purchases die-casting machines, materials, molds and other materials, and builds its own factories to produce die-casting parts; the other is the procurement model: the OEM directly purchases from die-casting manufacturers. For die-casting parts, the die-casting manufacturer purchases relevant materials, produces the die-casting parts, and then delivers them to the OEM.
Tesla, the current representative company of the self-research model, has begun to contact die-casting manufacturers. In the long term, due to the high cost of self-built factories and production lines for OEMs, and car sales may become a suppressing factor in production capacity utilization, the procurement model It is expected to become a long-term mainstream.
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Integrated die-casting layout and progress of some aluminum die-casting suppliers
Car companies such as Tesla, NIO, Xpeng, Ideal, Gaohe, Volvo and Great Wall have already deployed in the automotive integrated die-casting field.
In terms of new forces: Tesla's Model Y, which uses an integrated die-cast rear floor, has been officially delivered. Domestic NIO's ET5, which uses an integrated die-cast rear subframe, is about to be delivered. Xpeng, Ideal, Gaohe, and Huawei have in-depth cooperation. Cyrus Automobile's integrated die-casting has been put on the agenda and is expected to be launched in cars one after another in 2023. In addition, Xiaomi Automobile's models equipped with integrated die-casting are expected to achieve mass production in 2024.
In terms of traditional car companies: Foreign traditional car companies, including Volkswagen and Volvo, have a relatively long timeline for integrated die-casting layout and are expected to achieve mass production around 2025. Among domestic car companies, Changan and Great Wall have begun project recruitment. It is estimated that mass production will be achieved within the next two to three years.
Why Integrated Die Casting Is Transforming Modern Manufacturing
Integrated die casting ( Gigacasting / Megacasting ) has rapidly evolved from a bold manufacturing experiment into one of the most significant shifts in automotive and heavy equipment production.
Pioneered at scale by Tesla and quickly adopted by major global automakers (including Cybertruck, Zeekr, NIO, and Toyota), integrated die casting replaces dozens or even hundreds of individually stamped, welded, and riveted sheet metal parts with a single, massive aluminum structural casting.
Here is a breakdown of why this technology has taken the manufacturing world by storm.
1. Radical Reduction in Manufacturing Cost & Complexity
Traditional automotive body-in-white (BIW) production is a complex logistical puzzle. A single rear underbody historically required 70 to 100 individual steel or aluminum stampings joined by hundreds of spot welds, rivets, and structural adhesives.
TRADITIONAL BODY MANUFACTURING: [ 70+ Stamped Parts ] ──► [ Hundreds of Robots ] ──► [ Complex Welding Line ] ──► Final Sub-frame INTEGRATED DIE CASTING: [ Molten Aluminum ] ──► [ 6,000T - 12,000T Press ] ─────────────────────────► Single Cast Component
Integrated die casting collapses this multi-step assembly into a single injection cycle:
Fewer Assembly Robots: Eliminates the need for extensive robotic welding and riveting lines, cutting shop-floor footprint by up to 30%–50%.
Supply Chain Simplification: Reduces the number of individual part suppliers, part numbers (SKUs), and quality control inspections required across the supply chain.
2. Significant Weight Reduction & Increased EV Range
For Electric Vehicles (EVs), weight directly impacts battery efficiency and driving range.
Optimized Material Distribution: Unlike uniform sheet metal stampings, cast components allow engineers to vary wall thickness dynamically-placing metal only where structural strength is required and removing it elsewhere.
Aluminum vs. Steel: Replacing traditional multi-material steel sub-assemblies with high-strength aluminum alloys yields structural weight savings of 10% to 20% on the vehicle frame, directly translating to enhanced battery range or smaller, lower-cost battery packs.
3. Superior Structural Rigidity & NVH Performance
By eliminating joints, fasteners, and weld seams-which are inherent weak points for flex and stress concentration-integrated castings create an exceptionally rigid structure:
Higher Torsional Stiffness: A single monolithic casting significantly boosts overall vehicle body rigidity, improving dynamic handling and crash safety performance.
Improved NVH (Noise, Vibration, and Harshness): Fewer squeaks, rattles, and acoustic resonances occur over the life of the vehicle because there are no internal mechanical joints to loosen over time.
4. Dramatically Shorter Production Cycle Times
Traditional stamping and body assembly lines require several minutes per sub-assembly, with complex transfer mechanisms between stations.
A high-tonnage giga-press (ranging from 6,000 to 12,000+ tons of clamping force) can inject molten aluminum and output a fully formed structural underbody frame in under 120 seconds.
The Engineering Challenges Ahead
Despite its advantages, integrated die casting presents real-world trade-offs that manufacturers are actively working to solve:
| Challenge | Impact | Industry Solution |
| High Capital Expenditure | Ultra-large die casting machines and custom tooling require massive upfront capital. | High-volume vehicle platforms offset initial equipment costs quickly. |
| Repairability & Insurance Costs | Damage to a single section of a cast frame can be difficult to repair via standard body shops. | Modular crash boxes and localized bolt-on replacement sections. |
| Mold Thermal Fatigue | Immense heat and pressure wear down multi-million-dollar molds quickly. | Advanced heat-resistant die steels and conformal cooling channels. |
Integrated die casting is not just a trend-it represents the future of large-scale structural manufacturing, merging material science, extreme hydraulics, and automated design to unlock unprecedented factory efficiency.
