After the Euroguss 2024 fair, and as emerged in recent years, Gigacasting technology is gaining increasing interest among major automotive manufacturers.
The reason for this interest lies under the growing success that large castings provide within the Parts Production Process: cost reduction in assembly, less defects caused by components, limitation of the number of welding points, and, in general, a substantial lightening of the vehicle.
Gigacasting, Gigapresses, and Die-Casting in the automotive industry
According to recent forecasts(Alix Partners), the global market related to Aluminum casting currently amounts to about $73 billion, and it is expected to peak in 2032, reaching $126 billion.
Most of this market is closely tied to the production of components for vehicle manufacturing (cars, trucks, agri), and despite the gradual fading of the internal combustion engine and the increasing trend towards metal replacement, the outlook for the development of new technologies that ensure cost reduction, low environmental impact, and durable components is very positive.
What is Gigacasting?
Giga (or Mega) casting is a production technology that allows to inject and to mould large castings of special aluminum alloys with complex geometry and big dimensions (exceeding 2.5 m x 2 m).
The main production tool is the Gigapress, an aluminum injection press with a tonnage >6000 tons, although presses reaching 16000 tons are expected in the coming years!
The range of aluminum alloys suitable for this technology is still very limited (AlSi7CuMg for Tesla or AlSi7MnMg for Volkswagen or Volvo), but research into new alternatives is ongoing, and new solutions are plausible in the near future.
How much does a Gigapress produce? How much does it cost?
A press at full production does not exceed 120,000 pieces per year, and productivity can significantly decrease based on the geometry of the part. Thinner walls of the item require less solidification time, and therefore, the cooling cycle is shorter; conversely, significant massiveness increases the cycle time.
The cost of the press can vary from €5 million (6000 tons) to over €15 million (12000 tons, not yet installed), with additional costs for transportation (10% to 20%) and approximately €8 million in peripheral costs (installation, adjustment of existing equipment, equipment, etc.).
According to that, a manufacturer aiming 480,000 pcs./year will need to invest in the installation of at least 4 Gigapresses.
Who are the main Gigapress manufacturers?
The Gigapress production market is dominated by Asian manufacturers, considering that the Chinese L.K. Technologies owns the Idra Group in Travagliato, province of Brescia.
Other Asian manufacturers include Haitian Die Casting, Yizumi, Ningbo Haitian Precision Machinery, Shibaura (Japan), while in Europe, Bühler and Italpresse Gauss are present.
Who are the main users of Gigapresses?
Despite the magnitude of initial investments, many of the major players are turning to this technology, obtaining several advantages (such as lighter parts, vehicle lightening, fewer defects, environment-friendly process) but, above all, evident economic advantages (reduction of assembly and production costs).
The renowned Tesla had already invested a lot in Gigacasting and set the way for a large number of competitors who immediately perceived the technological (and economic) advantage. All the vahicle manufacturers are closely watching this new opportunity, including Mercedes, Volkswagen, Volvo, and probably Ford.
Handtmann foundry will use Gigacasting for GM’s Celestiq, while Lexus and Toyota will start production by 2026.
A special mention goes to Hyundai, which is developing a further innovative technology: Hypercasting (registered at the United States Patent and Trademark Office in August 2023), scheduled to start in 2026.
The Chinese company Nio is heavily relying on this technology and plans to apply it to all its models. Nio is also studying the production of Giga-castings in Magnesium alloys, but the results have not been made public yet. If successful, it would be possible to reduce the weight of the piece by 34% compared to Aluminum!