TPI unlocks 30% lighter Gigacastings

TPI Technology sent me this table detailing their upcoming products which will enable the production of Gigacastings that are over 30% lighter, stronger and more cost-effective.

The DreamPlast module can be attached to every “Giga Press size” die casting machine, up to 16,000 ton of Clamping Force, transforming it into a Thixomolding machine.

Two DreamPlast modules connected to a Giga Press can produce up to 70 kg of magnesium semi-solid slurry. This is enough to cast even the largest underbody Gigacastings in the automotive industry.

A big thanks to Thixotropic Piston Injection Technology!

More informative pictures in the gallery below!

Dongfeng Motor 10,000 ton Giga Press

The Wuhan Economic and Technological Development Zone recently announced that Dongfeng Motor Group has applied for the "Integrated Die Casting Industrialization Construction Project"

This project was announced in April, it consists in a 226 million yuan ($31.7 million) investment and will build a modern factory building and supporting facilities covering an area of 48,350 square meters.

The plan is to accommodate six Giga Press lines. The plant will be built all at once and is scheduled to be completed in June 2025 but the six production lines will be put into operation in stages.

The first phase of the project will see the installation of two 10,000 ton Giga Press production lines. They are expected to form an annual production capacity of 200,000 Giga Castings.

Yang Yanding, VP of Dongfeng's R&D Institute, in January: "Mastering integrated die-casting technology is the key way to realize the next generation of smart low-carbon architecture, and it is also the right direction to promote the deep integration of electrification."

Toyota will install a 9,000 ton Giga Press in 2024

Toyota will install a 9,000 ton Giga Press at its factory in Aichi, it will be one of the largest die casting machines in Japan.

The 9,000 ton machine will be manufactured by UBE Machinery, a Japanese company which has already made significant strides in this field, having produced 6,500 ton Giga Presses for various suppliers, including Ryobi.

This new 9,000-ton Giga Press represents a significant upgrade and will play a crucial role in Toyota's ambitious plans for the future. For now Toyota intends to utilize this advanced machine only for R&D purpose but at the same time the company announced it will produce the upcoming Lexus LF-ZC with both front and rear Gigacastings in 2026.

You can see a video from Toyota’s existing 6,000 ton Giga Press by clicking here

Volvo’s 8,500 ton Giga Press in China confirmed

In recent weeks, there have been rumors suggesting that Volvo may be in the process of installing Giga Press technology in China. These speculations have gained traction, and it has been confirmed that Støtek has indeed installed its mega casting furnaces at Volvo’s Chinese manufacturing facility, specifically at the Daqing plant.

This development marks a significant step forward for the company. A few weeks later, local publications provided further confirmation that the Daqing plant is undergoing a substantial upgrade. This upgrade includes the installation of Bühler Carat 840 units, which are Giga Presses boasting a clamping force of over 8,500 tons.

These powerful machines are not new to Volvo's operations; similar units have already been installed at the Torslanda plant in Sweden. Additionally, Volvo has plans to install two even larger 9,000 ton Giga Presses, this time produced by Idra in Italy, at their facility in Košice, Slovakia. This strategic move underscores the direction in which Volvo is evolving the Body-in-White of its vehicles. It is becoming increasingly clear that the company is committed to integrating Gigacastings into all of its future vehicle designs.

The first Volvo vehicle to benefit from this technology is the EM90 luxury minivan produced by Zeekr, the rear underbody gigacastings are produced using a 7,200 ton Giga Presses.

Financial Results

Yizumi

In the first half of 2024, Giga Press maker, Yizumi achieved operating income of 2.37 billion yuan ($332.7 million) a year-on-year increase of 20.82%; net profit reached 299 million yuan ($42 million) a year-on-year increase of 19.04%.

The die-casting machines performed well, with sales revenue of 417 million yuan ($58.5 million) in the first half of the year, accounting for 17.6% of the company's total sales, a year-on-year increase of 35.3%.

Wencan

In the first half of the year, Gigacasting supplier, Wencan reported operating income of 3.076 billion yuan ($431.8 million) a year-on-year increase of 20.07%; net profit of 81.820 million yuan ($11.5 million) a year-on-year increase of 488.19%.

The structural vehicle body parts business achieved 674 million yuan ($94.6 million) of revenue, a year-on-year increase of 128.47%.

Quick News

• Foton Motor is planning to use large, integrated automotive castings, also known as Gigacastings. When an investor asked if the company is working on implementing this technology, a Foton executive confirmed that they already have plans for it.

• The European Union has decided to adjust the tariffs on electric vehicles (EVs) imported from China, reducing the planned duties for several companies:

Tesla, reduced to 9% from an earlier planned 20.8%. BYD, decreased slightly from 17.4% to 17%. Geely, from 19.9% to 19.3%. SAIC, from 37.6% to 36.3%. These new tariffs are in addition to the existing 10% duty on battery electric vehicles (BEVs) imported into the EU. For companies that did not cooperate with the EU's investigation, the tariff was set at 36.3%, slightly down from 37.6%. Meanwhile, cooperating companies face a 21.3% tariff.

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