Honda Gigacasting Strategy

A model based on the Acura Performance EV Concept will become the first EV made at the Marysville Auto Plant in late 2025 and it’s going to be the first Honda model to adopt Gigacastings.

The IPU is a lightweight and thin new battery pack architecture which uses a die cast battery tray instead of one made with stamped sheets, reducing the number of components and integrating more parts into one or two pieces.

In Ohio, USA, Honda is renovating the Anna engine plant to accomodate six 6,100 tons Giga Presses made by BühlerPrince in Michigan. The six machines will produce the battery tray halves.

The dimension of the parts will vary depending on the size of the vehicle as you can see in the image and the two halves will be joined together using Friction Stir Welding.

In China, Honda has created a new brand called "Ye". The vehicles under the new brand will adopt this IPU as well but in an even more brazen manner as they'll use a 12,000 tons Giga Press and cast the entire battery tray in one piece.

So far Guangdong Hongtu is the only supplier with a 12,000 tons Giga Press running. The same supplier showed one of these battery trays at the Shanghai Expo (weight; 51kg).Honda will also introduced Front and Rear underbody Gigacastings starting from 2028.

Robotics in Gigacastings

SIR Soluzioni Industriali Robotizzate, based in Modena, Italy, is a leading international system integrator specializing in automotive and foundry sectors. They excel in customizing robotic solutions, recently expanding into the aluminum foundry market with robotic automation for Gigacastings.

The production of components using Giga Presses involve sophisticated coordination between the press and extraction robots, which are large, rail-mounted, and have high payload capacities to handle the casting process. These robots use multi-grip tools to extract large castings carefully gripping at predetermined points to prevent deformation. The robots are equipped with sensors to verify the correct casting of parts, including the main component, gating, and overflows. After extraction, further inspections might use additional sensors or vision systems to ensure quality. Once checks are complete, the system prepares for the next casting cycle, optimizing timing to enhance productivity.

Following extraction, the casting undergoes de-gating to remove excess material, either through a giga trim press after quenching in water or directly via plasma cutting at high temperatures, bypassing the need for quenching. Post de-gating, the part might be air-cooled, which is less stressful on the material, especially after removing the bulk of the gating system. For tracking purposes, a data matrix code is then laser-etched onto the component.

SIR has enhanced the de-gating process by integrating plasma torches onto robots, developed in partnership with plasma technology experts. This method is more economical and flexible than traditional trimming, allowing for varied cutting paths on different components, reducing costs, and requiring less post-cut finishing.

SIR has implemented an advanced robotic system for a major automotive client, focusing on the de-gating and deburring of large aluminum castings like front and rear subframes. This system uses robots for loading/unloading and plasma cutting to remove excess material. Following this, fine deburring is conducted using robots equipped with pneumatic spindles that feature compensation mechanisms for handling variable burr sizes, ensuring precision by adjusting rigidity as needed. These spindles can automatically change tools or even the entire end-of-arm tooling (EOAT) to accommodate different deburring requirements, including the use of abrasive belts for complex surfaces.

The deburring cells are designed with internal storage for tools and EOATs, allowing for seamless tool changes during the machining process. Tools are automatically maintained and replaced when worn, with systems in place for lubrication and verification of tool presence. Debris from deburring is managed through a conveyor system. After deburring, a 3D vision system inspects the parts to confirm quality. This comprehensive process from extraction to final inspection is optimized for productivity and quality, showcasing SIR's capability in providing sophisticated robotic solutions for automotive manufacturing.

For the full article click here

TPI SuperPlast

Cristian Bregoli, Sales Manager at Vantage Cast Europe, posted another update relative to the purchase of a their new magnesium Thixomolding machine for their foundry in Northern Italy.

From Vantage Cast’s website: “By converting die casting operations to TPI technology, it is possible to save up to 30% energy, up to 50% less material used and up to 50% weight reduction. This technology allows to obtain porosity tending to zero.”

This TPI SuperPlast module can deliver up to 5 kg of magnesium semi solid slurry in a single shot It can be attached to the side of any die casting machine and with little effort effectively transforming it into a magnesium thixomolding machine.

China Promotes Large Die Casting Machines

The Chinese Ministry of Industry and Information Technology recently issued the "Guidelines for the Promotion and Application of the First Major Technical Equipment” to promote the innovation, development and promotion and application of major technical equipment and strengthen the coordination of national policies. Among them, super-large cold chamber die-casting machines are included in the list as you can see below.

Currently LK Machinery, Haitian and Yizumi have produced die casting machines capable of applying more than 90,000 kN of Clamping Force while Lanson and Tederic have plans to do so in the not so distant future. Bühler, which has a production base in the country, has also produced its >9,000 tons Carat machines on Chinese soil.

You can find the full list on my Patreon.

EU EV Tariffs on Chinese EVs

The European Union is reportedly preparing to lower the additional tariffs on electric vehicles (EVs) imported from China before these tariffs officially take effect in November. According to Bloomberg, Tesla's duty rate might see a reduction from 9% to just under 8%. This adjustment comes after new information was provided by the companies involved.

The EU's move to impose these tariffs stems from an anti-subsidy investigation launched on October 4, 2023, targeting Chinese EV imports. Initially, provisional countervailing duties announced in June set a 21% average tariff for cooperating BEV producers, with specific rates for companies like BYD, Geely, and SAIC. By July 4, these rates saw minor reductions, and further adjustments in August specified Tesla's rate at 9%, down from a previously applied 20.8%.

These tariffs are additional to the existing 10% duty on Chinese exports, with final rates to be voted on by EU member states before November. The adjustments reflect ongoing negotiations and the EU's attempt to balance trade protection with its green technology ambitions.

If in order to avoid tariffs Chinese OEMs will be forced to build production plants in Europe then there might be some extremely good news for European tool makers and die casting suppliers. Almost every Chinese OEM plans to adopt large integrated castings in its future EV platforms.

This Week’s Gallery

Tesla Gigafactory Texas by Joe Tegtmeyer

Check out Tesla’s Gigacasting production capacity at its facilities around the world by clicking here