Five people familiar with the move said that Tesla combined a series of innovations to make a technological breakthrough that could transform the way it makes electric vehicles and help Elon Musk achieve his aim of halving production costs. The company pioneered huge presses with 6,000 to 9,000 tons of clamping pressure to mold its Model Y’s front and rear structures in what it calls a “gigacasting” process. The method slashed production costs and left rivals scrambling to catch up.
The company is now working on a giant casting machine capable of casting large parts in one go to boost efficiency even further. The Italian firm IDRA has shown a 9,000-ton version of the machine that Elon Musk has spoken of for the upcoming Tesla Cybertruck, and sources close to the company say it is being developed for that vehicle.
The key technology behind gig casting is a new kind of industrial sand that can be molded into complex shapes faster than the conventional metal foundry alloys used in automaking, which must be cast separately and assembled. The sand can also incorporate hollow subframes that save weight and improve crashworthiness. The idea is to enable Tesla to build a complete car in modular blocks that snap together rather than having to stamp and weld separate components.
The sources said the breakthrough could speed up the design of prototypes and cut production time significantly. A typical metal mold for a car component can take months to a year to develop and test. The people said the sand-casting process cuts that to two or three months.
It could also allow Tesla to do away with traditional dealerships and sell directly to customers, speeding up the process and lowering prices. Some established automakers are already eschewing the franchise sales model to attract younger buyers who prefer digital experiences in their cars.
Tesla must ensure the sand casting technique works reliably to pull off the feat. Its engineers have worked on the cooling processes for molten aluminum, new post-production heat treatments, and ways to shape the final part better. The company is also developing a faster 3D printer to make the complex industrial sand molds needed.
The breakthrough is a crucial step in the execution of the “unboxed” manufacturing strategy that Musk unveiled in March to produce tens of millions of more affordable electric vehicles over the next decade while maintaining profitability. It’s akin to how Apple founder Steve Jobs built the original iPhone for himself, starting with what he wanted very much.