Tesla is working on an innovative high-pressure casting technique to manufacture the underbody of its cars in one piece and significantly reduce production costs.
By combining high-pressure casting, 3D printing, and industrial sand, Tesla aims to shorten the development time for new vehicles and revolutionize the automotive industry.
The success of this technique could enable the production of more affordable electric cars and compel other manufacturers to take action.
Tesla Utilizes 3D Printing to Manufacture Car Underbody in a Single Piece.
Tesla is getting closer to achieving its goal of casting the underbody of its cars in one piece, according to sources. This disruptive manufacturing technique could significantly reduce production costs and revolutionize the automotive industry.
Traditional manufacturing techniques require up to 400 individual stampings that need to be welded, bolted, screwed, or glued together to create a complete unibody structure. In contrast, Tesla’s high-pressure casting method could eliminate the need for these separate parts, slashing manufacturing costs by up to 50 percent.
By casting the front, center, and rear sections of the car in one operation, Tesla aims to streamline the production process and reduce the time it takes to develop a new vehicle. While competitors typically take three to four years to bring a new car to the market, Tesla could achieve the same in just 18 to 24 months.
The use of high-pressure castings does present challenges, particularly in designing subframes with hollow sections that can withstand crash forces. However, Tesla is working with design and casting specialists in several countries to innovate and incorporate 3D printing and industrial sand into the manufacturing process.
The high cost and risks associated with creating molds for large components have deterred many automakers from adopting high-pressure casting. However, Tesla’s willingness to take on these challenges reflects its commitment to disruptive technologies.
If successful, Tesla’s high-pressure casting technique could pave the way for the production of a new, smaller electric car priced at around $25,000. This has the potential to put pressure on other manufacturers to respond and could further disrupt the automotive industry.
