When designing giga castings, incorporating a well-planned collision repair strategy is essential for enhancing vehicle maintenance efficiency. In the Tesla Model Y, for example, the single-piece rear floor casting includes a cut line feature, allowing for precise trimming after a low-speed rear impact. This enables a strategic rework by attaching a replacement part using high-strength structural rivets and bolts, offering a more efficient solution than the traditional bolt-on aluminum extrusion. By reducing process time, parts count, and complexity, this approach improves repairability while maintaining structural integrity. Such strategies should be a key focus in giga casting designs moving forward. #gigacasting #automotivedesignstrategy #designforservice
In a recent benchmark study comparing the rear gigacasting of the Zeekr 009 with the Tesla Model Y, we uncovered key differences in how these vehicles manage rear-end collisions. As the use of gigacasting becomes more widespread in vehicle rear bodies, concerns are growing around the behavior of these large components during collisions and their repairability. 👉 Our study revealed that the Zeekr 009 uses two longitudinal extruded profiles to protect the casting, which engage during medium-speed collisions, leaving the casting intact. Additionally, the fastening between the casting and the longitudinal beam is secured with screws, making replacement more straightforward. 👉 On the other hand, the Tesla Model Y relies on the legs of the rear casting as the main absorption element, featuring ribs and a wavelike pattern designed to compress during deformation. However, this design requires the entire module to be replaced even in low-to-mid-speed collisions, raising sustainability and #cost concerns due to the need to scrap large aluminum castings. We’d love to hear your thoughts on these differences and their potential impact on the future of gigacasting in automotive design. 🗨 Join the conversation and share your insights below! 👇 #Zeekr009 #TeslaModelY #gigacasting #repairability #sustainability
