What is Giga Casting? What is Giga Press 2.0? What about Giga Press 1.0 for that matter?
Giga Casting, also known as Giga Press, is a technological process of high pressure die-casting aluminum, for large assemblies. The process uses heat as well as pressure.
The big problem in finding out more about Giga Press is the Tesla fans. They often do not understand technology and resort to using buzz words to justify their purchases or fan-ness.
Tesla is known for branding existing tech processes, and calling it innovation. The Tesla “Unboxed Process” is merely the old way of building vehicles, prior to the assembly line (which Tesla still uses). The reason Tesla is moving back to this stationary method is due to Giga Press.
Giga Casting is the means by which Tesla hopes to build the as much of an entire car in one cast. The reason for this is to cut down on robot or human assembly, to cut costs and improve supply chain mechanics.
I do cover definitions, since Tesla fans (and Elon Musk himself) conflate terms. So I do talk about body-on-frame cars, and the innovation of the FWD drive train assembly. No, sadly exoskeleton cars are just unibody cars
There are some innovations at Tesla, and that is the means by which molds are made. Sand is often used when making molds, but using a 3D printer to make such molds is novel, and clever. Obviously 3D printed molds can yield complex geometries in die-cast parts
Giga-casting has flaws though. Many flaws. The biggest is the lack of repairability. Parts cannot be replaced, since its one single component. Much like the Rivian dent scandal, where a small dent cost $55,000 to repair, Tesla will suffer even worse when it comes to replacing panels and other parts. There seems to be this conflation between innovation and “fewer parts”. More parts means cheaper repairs, easier replacement of smaller components
Another flaw is the casting itself, that will result in deformation of the end product. Casting is rather rough to begin with, but works in heavy, smaller components, such as engine blocks, differential housings, etc. Casting the whole body of the car is why Tesla’s are known for very poor body fitment and panel gaps
Ultimately, Giga Casting only benefits the manufacturer, cutting their costs, while it increases repair costs, shortens vehicle life and durability. Aluminum as it is work hardens, resulting is stress risers, cracks and fissures that can total out a car. This is why in aviation, they replace entire aircraft skins, ribs, spars regularly. This cannot be done with single pieces made with a Giga Press. Any repair in effect becomes replacing the entire car
So, get ready for disposable cars, and of course, higher insurance costs due to the increased repair costs (if repairs are even cost effective to begin with!). And even if you don’t have a car made with a Giga Press, our premiums will still go up.
0:00 Giga-Casting and Giga Press 2.0
0:59 Lack of Objectivity in Early Tech
1:33 What is Giga-Casting? What is Giga Press? Marketing!
2:19 Tesla Unboxed Process Overview
4:48 Gigacasting 1.0 from Idra Italy
5:39 Exoskeleton? No. Unibody (unitbody) vs Frame (BOF) Construction
6:07 Fanboys and Tech Buzzwords
7:19 Multi-Directional Casting by Tesla
7:38 Obsession with “Fewer Moving Parts”
8:56 Gigacasting Cost Savings (and More Fanboy Lies)
9:39 Cast Molds Made by 3D Printing with Sand
10:02 Automotive News Europe – Giga Press Flaws
11:07 Automotive Innovation – Drive Train Layout Types and Comparisons
12:28 Inside EV – Specs, Specs, Specs!
13:51 Metallurgy Review – Work Hardening, Stress Risers, Cracks, Granules
16:25 Benefits of Giga Casting and Giga Press
16:46 Giga Casting Drawbacks – Rivian Unipanel Scandal – Repairability
17:11 Giga Press Tolerances and Body Fitment Issues
18:41 Insurance Rates Go Up
19:51 Diecast Metal Cracks Under Press
20:25 Steel vs Aluminum – Lessons from Aviation
21:46 Disposable Cars
22:47 Weak Economy Might End Giga Press
23:06 What is Cool in a Car?
24:50 Bloopers
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