Automotive integrated die casting is an automotive manufacturing process proposed and put into practice by Tesla. It redesigns and highly integrates multiple separate and scattered small parts in the original design, then uses a large die casting machine to perform high-pressure die casting at one time, and directly produces a complete large part without the welding process. Compared with traditional automotive manufacturing, automotive integrated die casting has advantages in manufacturing cost, production efficiency, labor cost, model development cycle, performance, materials recycling, etc.
Against the traditional concept that product and process design hinges on the existing conditions and capabilities, Tesla prefers reverse thinking. Taking automotive integrated die-casting as an example, Tesla determines how large the part can be to achieve the best effect, then deduces how much equipment, tooling and materials are needed. Afterwards, it cooperates with suppliers to develop new equipment, corresponding molds, materials and new processes. This kind of thinking has greatly inspired the innovation of the traditional industry and brought upheaval and the secondary innovation to the industry.
In terms of emerging automakers, Tesla has officially delivered Model Y with integrated die casting floors. NIO ET5 with an integrated die casting rear subframe is about to be delivered. In addition, Xpeng, Li Auto and HiPhi have put integrated die casting on the agenda, and they may apply it to vehicles in 2023.
