Now that everyone is back in office after the holidays, here is my After holidays update!

But before let me wish you all a Happy New Year! May 2025 bring you success, happiness, and exciting new opportunities.

Xpeng Models Update

Xpeng, the biggest Chinese believer in the Gigacasting technology has some exciting updates regarding its vehicle lineup.

Renewed P7

A camouflaged Xpeng P7 has been spotted in China, with reports indicating that Xpeng will release an updated version in 2025.

Currently, the P7 or P7i sedan is manufactured at the Zhaoqing plant in China, which uses conventional methods for the underbody manufacturing process.

I give it a low chance that this vehicle will use Gigacastings because, in my opinion, it makes more sense to continue amortizing the costs of the existing production line rather than investing in a new one, especially since the current line is relatively new.

Another option could be to build both the P7+ and P7i on the same new line that uses Gigacastings for the P7+. However, this would mean moving the entire P7i production to another factory and completely scrapping the almost brand-new production line in Zhaoqing.

New G7

Xpeng has announced, with the release of a new rendering, the launch of their new SUV called the G7.

In this case, I expect the vehicle to use both Front and Rear Underbody Gigacastings (FUB & RUB). Every high-volume vehicle released by Xpeng since 2022 incorporates these, including the G6, the X9, and their latest model, the P7+.

In my opinion, it would make even more sense to leverage the existing installed capacity from the 5 Giga Presses from 7,000 to 16,000t installed by Xpeng and its supplier, Guangdong Hongtu.

Given the production volume of their existing vehicles, the Giga Presses are not running at their potential maximum capacity, so using them to produce castings for the G7 is a logical step.

GF Casting Solutions US

GF Casting Solutions is building a new facility in Augusta, Georgia, USA and will begin operations in 2026.

GF's first 6,100-ton Giga Press is operational at their facility in Shenyang, China. The machine was manufactured by the Chinese division of Bühler Group Die Casting.

The new facility in the United States will also utilize approximately 6,000t machines, assuming plans haven't changed.

The goal of the project is to supply large structural aluminum castings for the automotive industry. The cost of the investment is $184 million with plans to hire 350 people.

BühlerPrince is the only American die casting machine manufacturer currently making machines over 6,000 tons and is expected to supply these machines to GF.

Bojun Tech and Li Auto Launch First RUB Gigacasting

Chinese supplier Bojun Tech has marked a significant milestone by producing their first Rear UnderBody (RUB) Gigacasting.

This achievement is the result of a collaboration between Bojun Industrial Technology and the Chinese OEM, Li Auto.

Details about the RUB casting are sparse, but it is known that it was manufactured using LK Machinery's 9,000-ton Giga Press. Mass production is slated to begin in Q2 2025.

It remains unclear whether this casting is intended for a new model or as a refresh for Li Auto's existing lineup.

World’s First Double Injection 3,000t Magnesium Thixomolding Machine

On December 28, 2024, Waffer Technology held a grand commissioning ceremony for its Maanshan Phase IV project (Waffer Technology Maanshan) and the World's First 3,000t Double-Shot Magnesium Thixomolding Machine.

This pioneering 3,000t magnesium thixomolding machine is capable of producing ultra-large-sized parts up to 2 meters in length, suitable for structural or interior automotive parts post-painting, significantly expanding the application range of magnesium alloys in medium and large automotive components.

The molding machine employs twin screws to simultaneously melt magnesium alloy raw materials, boasting a melting capacity twice that of a single material tube, exceeding 10 kilograms per shot. This design not only reduces energy consumption by more than 20% but also increases efficiency by over 30%. It enables "one mold, two cavities" production, allowing for the simultaneous manufacturing of two sets of automotive dual-screen display brackets and housings and has shown considerable advantages in molding automotive crossbeam brackets (CCB). Furthermore, by not requiring a melting furnace or protective gas, the machine meets goals of enhanced efficiency, energy conservation, and environmental protection, embodying Waffer Technology's commitment to green manufacturing.

Currently, Waffer Technology operates nearly 50 magnesium alloy semi-solid injection molding machines, with models ranging from 280 to 3,000t. Although the presentation did not specify the manufacturer of this machine, as far as I know representatives from Japan Steel Works were present at the event.

Tesla Model Y “Juniper” Unveiled

On Tesla's website tesla.com/en_au/modely we can see that the New Model Y is even quieter thanks to;

"Redesigned body castings which reduce parts form 70 to 1 for fewer gaps"

The Model Y already had Rear Gigacastings which reduced the number of parts from 70 to 1 so this perhaps refers to the use of new Front UnderBody Gigacastings? 🤔

We'll certainly find out when deliveries begin or maybe even before, in the meantime here's what we know:

1) All Model Ys are now built with Rear Gigacastings. The manufacturing process and applies to all factories: Fremont, Shanghai, Berlin, and Austin.

2) Only the versions with the Structural Battery pack used Front Gigacastings.

3) Tesla has two types of structural battery packs:

• Tesla 4680 cells (nickel-based cathode) at Giga Texas

• BYD Blade (LFP) at Giga Berlin

4) The Model Y with both Front and Rear castings, along with the Structural Pack, has been discontinued at both factories.

5) On Tesla's website, in the "Discover the New Model Y" section, there's a rendering of the Body-in-White (BIW) which shows the absence of Front Gigacastings.

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