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Why has automobile integrated die-casting technology not been popularized in the automobile manufacturing industry?

By, CoolMotor

• 2023-11-16
• 74 View

To put it simply, integrated die-casting technology integrates parts originally composed of multiple stamped parts into one part.

There are several reasons why this technology is not widely used in the automotive manufacturing industry:

Changes in component materials: Tesla Model Y uses an all-aluminum body, which provides good basic conditions for integrated die-casting technology. However, the number of all-aluminum body cars currently available to ordinary consumers on the market is very limited. In addition, integrated components, such as the rear floor, involve the connection of steel and aluminum parts, which is more difficult than traditional welding processes. This has brought great obstacles to the promotion of integrated die-casting technology. Coupled with design restrictions, even the Model 3 with a steel-aluminum hybrid body does not use integrated die-casting technology. This may be because even for technologies with cost advantages, manufacturers may not necessarily adopt them.

Changes in the number of parts: Previously, to assemble parts A, B and C into an assembly through welding, these three parts needed to be stamped out first and then welded. After adopting integrated die-casting technology, only one component is needed, which greatly reduces management costs. When it comes to the integration of more parts, the cost advantage of car companies becomes even more obvious.

Changes in parts processing procedures: Due to the reduction in the number of parts, processing steps such as stamping procedures, transportation and storage, and welding procedures will be greatly reduced, reducing processing costs.

Improvement of material utilization: Aluminum stamping parts also need to go through the stamping forming process. The higher the utilization rate of materials, the lower the cost. Integrated die-casting technology can greatly improve material utilization and reduce material costs.

Integrated die-casting technology has many advantages, but why has it not become popular?

The reason is that once integrated die-casting parts malfunction and require repair, the repair cost is very high. This may be related to the barriers to component connection I mentioned earlier. However, these are only factors that vehicle manufacturers need to weigh, but they are not the key factors limiting the popularity of integrated die-casting technology. Although the maintenance cost is high, integrated components are difficult to deform in daily small collisions, and steel-aluminum connection technology is also feasible (such as riveting and fusion welding). The problem is that if integrated die-casting is not considered in the product development and design stage of mass-produced models, it will be almost impossible to implement it after mass production.

In fact, technological changes in the automotive industry usually require a long cycle. From the planning of the vehicle manufacturer, the inspection of suppliers, to the installation and debugging of equipment, to the analysis, design, manufacturing, debugging and small-scale trial production of molds, only then can mass production be achieved. Not to mention that this is a new technology and the relevant talents on the market are very limited.

However, some vehicle manufacturers have already begun to deploy integrated casting technology, so it does not mean that this technology has not become popular. It just takes time.