There aren’t many ways for a car manufacturer to cut costs by 40 percent. At least in Tesla’s case, we’re not talking about more optimized software or faster processors and more precise robotic arms. We’re talking pure and brutal power – like 9,000 tons of downforce. Such are the capabilities of the world’s largest foundry press, which Elon Musk’s company uses.
The giant machines allow the replacement of 60 individual components with a single module, thus simplifying the entire production process. Tesla and their Italian partners IDRA are pioneers in the use of so-called gigapresses for the production of complete car chassis from aluminum alloy. Currently, Toyota, GM, Hyundai, Volvo and Chinese companies are looking for ways to implement large presses into their production processes.
Musk: Tesla could sell 2 million cars this year
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It is no coincidence that electric cars are the first to use the new technology – their batteries are responsible for between 25% and 40% of the total price of the vehicle. “You have to make the price of the rest lower,” IDRA general manager Ricardo Ferrario told Reuters. According to him, simplified production is the key to making electric cars more affordable.
The company, which is Chinese-owned since 2008, has been producing gigapresses since 2016, and its competitors in the market are from Europe as well as Japan and China. Its flagship is the Gigapress 9000, which has 9,000 tons of force and is as big as a house. Already used by Tesla – for the Cybertruck. Smaller models from the same manufacturer make it possible to produce a Tesla Model Y in 10 hours.
According to Ferrari, IDRA has contracts with three car companies and as many tier one parts manufacturers. Among them, according to Reuters, is Hyundai.
Critics warn that the stakes are high – one mistake leads to a much larger marriage – but in the current climate of increasingly expensive raw materials, businesses are looking for ways to preserve their margins. That is why, at least for now, VW is in no hurry to implement the technology, and BMW has not even shown any interest in it.
Tesla invests more than $700 million in the American gigafactory
Elon Musk’s car company plant is located in Texas
However, according to experts, about 80% of manufacturers are likely to use large die casting presses in 2035 because of the savings they bring.
