Giga Press

The term refers to the large casting machines that Tesla uses when it comes to electric car production. Specifically at the Giga factory in Berlin, Germany. Giga Press is a series of aluminum die-casting machines manufactured by Idra Group in Italy. They are notable for being the largest high-pressure die-casting machines in the world, with a clamping force of 55,000 to 61,000 kilonewtons. Each machine weighs 410-430 tonnes. Wikipedia 

Model: OL 6100 CS (Idra); DCC 6000 (LK)

Dimensions: 19.5 m x 5.9m x 5.3m; 64 by 19 by 17 feet

Weight: 410-430 tonnes; 900,000-950,000 lb

Invented: -2018

Fuel source: ElectricIn 2021, Tesla will only have a few major factories using this technology to manufacture various parts for their cars. This press is a large casting machine that can produce certain automotive components such as structures, chassis, and other parts in a single piece. Unlike traditional manufacturing methods, it does not require multiple smaller parts to be welded together, which is time-consuming and inefficient. The hope was that this process would increase manufacturing speed, reduce costs, and enhance the overall structural integrity of electric vehicles.

But after a few years of development, something new has changed. The Giga press this one die casting machine, which is not a new or unique process of casting has been the entire gas stove car manufacturing main content, and industry history most also related to it, the casting process is used to form the engine. Critical components such as cylinder blocks and gearbox housings, but integrated casting has never been implemented for the large structural parts of the frame. Fortunately, for the Italian sub-species producers, some very clever people have built this new integrated die-casting machine, and within ten years from now, when electric motors and batteries need to dominate, engine blocks and cylinder heads will no longer be needed for automotive components. If companies are going to stay relevant and remain at the forefront of the industry, then they need to push this technology forward quickly, and they have to do it faster and bigger to cast on the largest scale possible to keep their production running. And Giga Press was born thanks to a partnership between two very large companies that worked together with a relentless dedication to innovation to come to fruition.

Tesla’s pursuit of the integrated body press process is due to the lightweight of automobiles, which is a common research topic in the automotive industry. Tesla’s integrated pressing is a kind of car that is lightweight, different parts can have different degrees of contribution. In the new energy automobile body in lightweight design demand driven by the body key parts towards thin wall high performance, large-scale development direction, die casting technology also from small pieces gradually to large-scale, integrated development. Integral die-casting benefits, in terms of manufacturing, can reduce the factory construction time, shorten operating costs, reduce manufacturing costs and the number of molds, etc., can reduce the cost of all manufacturing environments, in addition to this, also can greatly reduce the number of developers, management personnel. In addition to the advantages of the reduction of spending, for the body, the integrated casting does not produce intention, also reduces the work of stamping and welding, reduces the manufacturing process, and the quality is easier to control.

Hearing all of the above, you might think that this is a technology that is popular with everyone. However actual consumers have mixed feelings about this technology. Because for consumers, the vehicle is a kind of wear and tear goods, if the vehicle has some collision or mass then, the car accident needs to carry out extensive repairs. Giga press also means that when a part of the vehicle has damage and needs to be repaired, they need to change the entire body made of integrated casting. Undoubtedly for consumers, the cost of repairs increases substantially, which is a concern for many consumers. Exacerbating the cost of use, consumers may choose other vehicles. And there are very few manufacturers that use one-piece pressing, because one-piece pressing has requirements for the material, which can only be suitable for aluminum alloy, and the cost is very much higher than stamping. This also means that the liquid press, applicable to very few models, must be the all-aluminum body of the car can be used. Now on the market circulation of the car is relatively rare all-aluminum body. In addition to the above for the use of consumers spending increased most vehicles will have insurance. After you report a claim to the insurance company, because of the rising cost of repairs, the insurance premium increases to pay for the unibody die casting. So now the insurance company has dramatically increased the premiums on the Tesla and kept the rest as is.

Overall, the Giga press is a new milestone in vehicle lightweighting, but many issues still need to be considered.

Picture retrieved from https://en.wikipedia.org/wiki/Giga_Press

This article is a part of the class
“751309 Macro Economic 2”
supervised by Asst. Prof. Napon Hongsakulvasu
Faculty of Economics, Chiang Mai University

This article was written by
Qingyu Zhao 641615515