Tesla Plans to Revolutionize Electric Car Production With New Breakthrough

In a world where the race to produce the most efficient electric vehicles (EVs) is intensifying, Tesla is once again setting itself apart.

by Faruk Imamovic
Tesla Plans to Revolutionize Electric Car Production With New Breakthrough
© Getty Images News/Leonhard Simon

The innovative automaker is reportedly on the brink of a significant technological breakthrough that could dramatically change the way electric vehicles are produced and significantly cut their production costs, according to insiders familiar with the matter.

Gigacasting: Revolutionizing EV Production

Tesla, always at the forefront of groundbreaking technology, introduced the world to the "gigacasting" process for its Model Y. This advanced manufacturing method employs colossal presses exerting 6,000 to 9,000 tons of clamping pressure to mold the vehicle's front and rear structures.

The end result? A dramatic reduction in production costs and a leap ahead of competitors who are now racing to match this level of efficiency. However, Tesla's ambitions do not stop there. The company is reportedly nearing an even more audacious innovation.

The new process would enable Tesla to die-cast almost the entire complex underbody of an EV as a singular unit. To put this in perspective, traditional cars are assembled using approximately 400 separate parts for their underbody.

The Potential Impact on the Automobile Industry

Terry Woychowski, president of the U.S. engineering firm Caresoft Global and a former GM veteran with over 30 years of industry experience, weighed in on this potential paradigm shift. "If Tesla managed to gigacast most of the underbody of an EV, it would further disrupt the way cars are designed and manufactured," he explained.

Woychowski didn't mince words about the implications, calling it an "enabler on steroids." However, he also highlighted the significant challenges this innovative process poses. "Castings are very hard to do, especially the bigger and the more complicated," Woychowski noted.

As the industry waits with bated breath, sources have indicated that Tesla could finalize its decision to adopt this ambitious one-piece die-casting method for the platform as soon as this month. However, like any pioneering venture, there remain uncertainties.

Even if Tesla decides to forge ahead with this plan, the final design could undergo changes during the design validation phase. This move, if successful, could cement Tesla's position as the undisputed leader in EV production technology, potentially leading to more affordable and efficiently produced electric vehicles for consumers worldwide.