{"id":1176,"date":"2021-08-03T15:43:45","date_gmt":"2021-08-03T15:43:45","guid":{"rendered":"https:\/\/moldie.net\/?p=1176"},"modified":"2024-04-17T11:26:29","modified_gmt":"2024-04-17T03:26:29","slug":"how-high-pressure-die-casting-makes-simpler-lighter-cheaper-teslas","status":"publish","type":"post","link":"https:\/\/moldie.net\/how-high-pressure-die-casting-makes-simpler-lighter-cheaper-teslas\/","title":{"rendered":"How High-Pressure Die Casting Makes Simpler Lighter Cheaper Teslas"},"content":{"rendered":"

Look at any ad for a new car model, and you\u2019ll notice that car makers seem to be in a race to make the lightest cars without compromising space, quality, and comfort. To explain why every automaker wants to make lighter cars, the car division of USNews.com notes<\/a> that \u201cThe less mass something has, the less energy is required to move it.\u201d<\/p>\n

Like all other carmakers, Tesla is also taking measures to make simpler, lighter, and cheaper cars. In its characteristic Tesla fashion, the company is doing this with great fanfare, announcing<\/a> via a Tweet on February 5, 2021, that it has acquired the \u201cWorld\u2019s biggest die casting machine.\u201d The company says<\/a> that this machine \u201ccan cast front & rear vehicle underbodies in a single piece each \u2014 down from 70+ parts for same sections previously.\u201d<\/p>\n

This article looks at how Tesla plans to use high-pressure die casting to improve its cars by making them simpler, lighter, and cheaper. We start by defining high-pressure die casting.<\/p>\n

What Is High-Pressure Die Casting? <\/strong><\/h2>\n

\"What<\/p>\n

Die-cast molds<\/a>, especially high-pressure die-cast (HPDC) molds, are at the forefront of a revolution in how cars are produced. But what is high-pressure die casting?<\/p>\n

To understand high-pressure die casting, let\u2019s start by defining die casting. The online encyclopedia Britannica.com defines<\/a> die casting as \u201cforming metal objects by injecting molten metal under pressure into dies, or molds.\u201d The dies and molds are made from heat-resistant steel.<\/p>\n

The high-pressure part denotes that the molten metal is forced under pressure into a die cavity. The properly locked cavity holds the molten metal until it solidifies into the desired shape.<\/p>\n

Isaiah Richard writes for TechTimes.com, a website that reports on the latest industry, science, and technology developments and innovations. He refers to high-pressure die casting<\/a> in the context of car manufacturing: \u201cA die-cast machine is like a press that forms the metal around a certain cast, containing all the details that the vehicle needs.\u201d<\/p>\n

Introducing the World\u2019s Biggest Die Casting Machine<\/strong><\/h2>\n

When Tesla announced in February 2021 that it has the world\u2019s largest die casting machine, those who know Elon Musk were not surprised. For instance, in his article published by Entrepreneur.com, Randy Garn says<\/a> that \u201cNo means nothing\u201d to Musk. This means that he believes that anything can be done, even when many people say no.<\/p>\n

When he writes for TorqueNews.com about the die casting machine used by Tesla, Jeremy Johnson can\u2019t hide the fact that he is impressed. He says<\/a>, \u201cTesla is making cars the same way toy cars are manufactured with automation, and it\u2019s like 3D printing!\u201d Adding, \u201cIt\u2019s like a Giant High Tech Waffler Maker!\u201d<\/p>\n

Tesla may have the biggest die casting machine on earth. However, Musk himself indicates<\/a> that \u201cMaking this work has been \/ still is super difficult, but it\u2019s a revolution in car body design & production \u2013 lighter, tighter, better NVH, higher precision, lower capex, lower unit cost.\u201d<\/p>\n

FoundryMag.com, a website that contains news about metal casting technology, provides some insights into Tesla’s reasoning behind its decision to turn to die casting at a massive scale. The site reports<\/a> that Musk had indicated during an interview \u201cthat automotive body design and manufacturing is fraught with inefficiencies because such assemblies involve multiple cast and\/or stamped pieces welded or joined together.\u201d<\/p>\n

Size of a Small House<\/strong><\/h2>\n

Edward Taylor and Paul Lienert of Reuters.com describe<\/a> Tesla\u2019s high-pressure die casting machine, called the Gigapress, using the words \u201csize of a small house.\u201d<\/p>\n

The Italian company IDRA Srl supplies the machine. The company boasts<\/a> that it is the \u201cfirst company worldwide that can offer \u2026 Giga Presses on the market.\u201d<\/p>\n

If you are wondering why Tesla went to IDRA Srl for the machine, you probably haven\u2019t seen the latter\u2019s innovative goals<\/a>:<\/p>\n

    \n
  • Create solutions for the hydraulic plant that can save energy consumption by up to 40%.<\/li>\n
  • Make it possible to manufacture large structural castings with thinner walls by enabling more stable injection conditions in all phases.<\/li>\n
  • Improving aesthetics and modularity by introducing a deep evolution in the body of cars.<\/li>\n
  • Making it simpler to commission machines at the client\u2019s premises by developing novel architectures for the \u201cdie casting cell with a central control hub monitoring the press and all other peripheral equipment.\u201d<\/li>\n<\/ul>\n

    Thomas Fritsch, Chief Editor at Foundry-Planet.com, says<\/a> that \u201cGigapress is not just XXL, it signals the new way of thinking in die casting.\u201d<\/p>\n

    How Does the Gigapress Help Tesla Make Simpler Lighter Cheaper Teslas?<\/strong><\/h2>\n

    So, what\u2019s the fuss with the giant high-pressure die casting machine at Tesla? Taylor and Lienert have an idea. They say<\/a> that the high-pressure die casting machine will solve the challenges met by companies attempting to introduce more aluminum into the car\u2019s frame.<\/p>\n

    Taylor and Lienert note<\/a> that \u201cAluminum has proven cumbersome to use in large components because it is difficult to stamp into complex shapes.\u201d Adding, \u201cTo get intricate ridges and other shapes, aluminum pieces have needed to be glued or riveted, since welding deforms the metal.\u201d<\/p>\n

    And how will pressure die casting solve this challenge? Again, Taylor and Lienert have the answer<\/a>: \u201cInjecting molten aluminum into a cast and having robots pull out the molded metal allows Tesla to combine several manufacturing steps.\u201d They add that this has allowed Tesla to reduce the number of parts in the rear underbody to two parts, forming the biggest casting ever seen in a car company.<\/p>\n

    Fritsch agrees that the Giga Press will make things cheaper for companies that use it. He writes<\/a>, \u201cTwo Giga Presses are cheaper than four large 4000t machines and considerable savings can be achieved in the entire assembly area.\u201d Adding, \u201cOne speaks of about 20% based on the entire process with fixations, robots and quality inspection of the individual parts.\u201d<\/p>\n

    Better Quality <\/strong><\/h3>\n

    The Gigapress also makes it easier to manage quality. In this regard, Fritsch says<\/a>, \u201cThe keyword is \u2018quality\u2019 — the arguments mentioned here are better features, the stability and stiffness of the casting part, and also the simplification of the quality control, which is a check performed through one test code for every 3 cast parts.\u201d<\/p>\n

    Friendly to the Environment <\/strong><\/h3>\n

    In a video<\/a> posted on YouTube, IDRA\u2019s General Manager, Riccardo Ferrario, refers to saving the planet. He says, \u201cIf we dare to dream big, and we are convinced about what we\u2019re doing, we can change the world towards a better future for our children and our grandchildren.\u201d<\/p>\n

    You can see Ferrario\u2019s full video below.<\/p>\n