Reuters has learned that Tesla is close to perfecting a way to make large high pressure castings for its automobiles.
. Now, according to sources, Tesla is focusing on pressure casting the front, center, and rear sections all in one operation.
Terry Woychowsk, who worked at General Motors for 3 decades, knows a thing or two about manufacturing automobiles. He is now the president of U.S. engineering company Caresoft Global. He tellsthat if Tesla manages to gigacast most of the underbody of an EV, it would further disrupt the way cars are designed and manufactured. “It is an enabler on steroids. It has a huge implication for the industry, but it’s a very challenging task.
Many automakers have deemed the cost and the risks to be too high, especially since a design might need half a dozen or more tweaks to achieve a perfect die from the perspective of noise and vibration, fit and finish, ergonomics and crashworthiness. But risk is something that seldom bothers Elon Musk, who was the first to make rockets fly backwards.Tesla reportedly has turned to firms that make test molds out of industrial sand with 3D printers.
The casting specialists overcame that by formulating special alloys, fine tuning the molten alloy cooling process, and coming up with a post-production heat treatment, three of the sources said. Once Tesla is satisfied with the prototype sand mold, it can then invest in a final metal mold for mass production.has given it a perfect opportunity to cast an EV platform in one piece, mainly because its underbody is simpler. Small cars don’t have a big “overhang” at the front and the back.
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