Six large-scale, high-pressure
"Gigacasting" presses have been installed by Honda of America at the Anna (Ohio) Engine Plant as a core manufacturing element of the EV Hub the automaker will launch later this year.
Honda's EV batteries will be enclosed in high-pressure diecast aluminum cases that will be gigacast on the new, 6,000-ton machines and will be the largest parts Honda has ever produced. Future Honda EVs are expected to incorporate gigacast front and rear vehicle structures, which is similar to Tesla’s breakthrough use of gigacastings in its electric vehicles.
Gigcasting refers to high-pressure diecasting operations developed to produce large-dimension parts that allow automakers to minimize subassembly for vehicle structures, saving production time and labor costs. Hundreds of individual parts, fasteners, welds, etc. are eliminated, along with weight savings, with highly accurate castings. Honda suggested that future gigacast parts could include body frames and internal-combustion or hybrid-electric engine components.
Numerous automakers are adopting gigacasting, including Tesla, Toyota, Honda NIO, Geely (and its brand Zeekr), and Xpeng.
Mercedes will utilize gigacasting, in its electric vehicle development, particularly for the
EQXX concept. They are using it to create single-piece rear structures and other large components, aiming for lighter, stronger, and more efficient parts compared to traditional methods.
The EQXX boasts a range of over 620 miles (1,000 km) on a single charge. This impressive range is achieved through a combination of factors, including a highly efficient electric drivetrain, lightweight design, and optimized aerodynamics. Charge twice a month? Nice...
