Gigacasting & Megafactory Manufacturing
70 pieces of steel become 1 piece of aluminum.
Explore this event on the interactive timeline →Tesla revolutionized heavy manufacturing by deploying "Giga Presses"—massive die-casting machines with up to 9,000 tons of clamping force. Instead of welding dozens of stamped steel parts together to build a car frame, liquid aluminum is injected into a mold to create a single, massive structural casting in milliseconds.
Key Numbers
- Parts Count (Traditional)
- ~70 Welded Parts
- Parts Count (Gigacast)
- 1 Solid Casting
Verified Facts
- For the rear underbody of the Model Y, Gigacasting successfully replaced approximately 70 individual parts with a single casting, eliminating hundreds of robots and welding steps from the assembly line.
- By heavily reducing the weight and complexity of the vehicle structure, manufacturing costs plummeted, allowing electric vehicles to reach price parity with combustion engines.
- Following this breakthrough, the entire global automotive industry (including Toyota, Ford, and Hyundai) began scrambling to deploy "hypercasting" to remain competitive.