farshid hesami’s Post

Imagine building a car’s frame in a single piece instead of assembling hundreds of parts! That’s gigacasting — a groundbreaking process revolutionizing the automotive industry. Here’s how it works: 🔹 Single-Piece Casting: Gigacasting uses giant die-casting machines to produce large vehicle sections, like the rear underbody, in one solid piece, reducing the number of parts and simplifying assembly. 🔹 Faster Production & Lower Costs: With fewer parts and faster assembly, gigacasting speeds up production and reduces costs, making car manufacturing more efficient. 🔹 Stronger Structure: One-piece casting improves the vehicle’s strength and durability, boosting safety and reliability. 🔹 Eco-Friendly Innovation: This method cuts down on energy and materials, reducing the environmental footprint of vehicle manufacturing. Pioneered by Tesla with the Giga Press, gigacasting is reshaping how vehicles are made, paving the way for faster, stronger, and greener cars! 🌍✨ #Gigacasting #Tesla #CarManufacturing #AutomotiveEngineering #Innovation #SustainableDesign #SkillLync #ElectricVehicles #FutureOfCars #EngineeringMarvel

Advancing Gigacasting Repairs (New Techniques Improve Tesla Model Y Sustainability and Cost-Efficiency)  Follow me for more technical insights: https://lnkd.in/evN3jc94  The video featuring John Sweigart, CEO of Evolve EV Specialists, provides a detailed breakdown of the repairability of Tesla Model Y gigacastings—challenging the earlier assumption that these massive cast components were irreparable. With advancements in repair methodologies, Tesla's gigacasting approach becomes more sustainable and cost-effective.  >>> Key Technical Aspects of Gigacasting Repairs: - Precision Inspection with 3D Digital Measurement:   The repair process begins with the removal of the quarter panel to access the rear gigacasting. Evolve EV uses 3D measurement tools to ensure that all structural points align precisely with Tesla’s manufacturing specifications. This guarantees that even slight misalignments are detected before further repairs.  - Advanced Visual Inspection for Cracks and Distortion:   Sweigart explains that aluminum castings may bend under impact but are prone to shattering under severe stress. Therefore, a comprehensive inspection is conducted to identify cracks, particularly in critical ribbed areas.  - Cost-Effective Repair Methods with Modular Replacement:    If damage is detected, the repair strategy involves cutting out the damaged section and attaching new pieces using structural adhesives, rivets, and backing plates. This method avoids the need for full component replacement, significantly lowering repair costs.  - Heat Map System for Repair Zone Identification:   A heat map system categorizes areas of the gigacasting based on their repair eligibility. While red zones were initially non-repairable, evolving standards now allow for limited repairs in certain areas with Tesla engineering approval.  >>> Expanded Repair Capabilities: - Welding and Backing Plate Applications:    - Cracks under 50 millimeters can be welded directly in specific areas.    - For cracks up to 30 millimeters, backing plates provide additional structural reinforcement, expanding repair possibilities and reducing waste.  - Enhanced Sustainability and Repair Efficiency:   The ability to repair instead of replacing entire castings offers a sustainable solution by reducing scrap material and allowing vehicles to return to service faster, aligning with Tesla’s long-term goals.  Read more technical article below : 👇 👇👇👇👇👇👇👇 https://lnkd.in/dmt4fUMq #Tesla  #Gigacasting  #EVRepair  #AutomotiveInnovation  #SustainableManufacturing  #AdvancedEngineering  #ProductionEfficiency

Highly interesting post on the question of the reparability of large structural castings after a crash. Yes at ACTech GmbH we do prototypes for large structural castings and we do like them. First of all I noticed how many parts need to be removed before you even can reach the casting. BUT, that would be the same effort on a conventional car and that alone can make a repair too expensive for an older car. Cut lines for repairs are a clever idea. Also welding the casting (in place) can make repairs more affordable. And a big one, it seems the casting is often still intact when a traditional structure needs repair. The engineers at Tesla managed a solid design with their "Gigacasting". I'm waiting to see long run data if cars with large structural castings are more likely to be unrepairable after an accident. #gigacasting #design #engineering

Tesla Cybertruck: A Paradigm Shift in Automotive Engineering...(Engineering valuable insights) _____________________________________________________________________________ The Tesla Cybertruck is revolutionizing the automotive industry with its futuristic design, versatile features, and cutting-edge technology. From its ultra-hard stainless steel exoskeleton to its advanced Autopilot system, the Cybertruck sets a new standard in durability, performance, and safety. Engineers, key insight! This vehicle showcases the power of unconventional design, multi-functional engineering, and continuous technological improvement. Let's drive towards a more innovative and sustainable future together. Learn more about how the Cybertruck is redefining automotive engineering! from my LATEST ARTICLE. #Engineering #Technology #Innovation #Sustainability #Tesla

𝐓𝐡𝐢𝐬 𝐯𝐢𝐝𝐞𝐨 𝐢𝐬 𝐭𝐡𝐞 𝐩𝐞𝐫𝐟𝐞𝐜𝐭 𝐞𝐱𝐚𝐦𝐩𝐥𝐞 𝐨𝐟 𝐨𝐧𝐞 𝐨𝐟 𝐄𝐥𝐨𝐧 𝐌𝐮𝐬𝐤'𝐬 𝐦𝐨𝐬𝐭 𝐟𝐚𝐦𝐨𝐮𝐬 𝐪𝐮𝐨𝐭𝐞𝐬 💡 ➡️ “The most common error of a smart engineer is to optimize a thing that should not exist” In the first part of the video we can see robot arms seam sealing the chassis of a car, which is a common process for cars made with hundreds of stamped sheets welded together by thousands of welds. This is for protecting the car against corrosion and leaks This was marketed as “seamless perfection” and as an “innovation” But what is really happening is that engineers spent countless hours optimizing a process that SHOULDN'T EXIST! 𝐖𝐡𝐲?! ➡️ Because a car underbody made with only 2 pieces using Gigacastings eliminates thousands of hyper optimized micro and macro processes and save companies space, time, labor and ultimately thousands of $$$ per car 🚀 Just like the Model Y, the Cybertruck and Tesla's future vehicles It is no coincidence that OEMs and suppliers around the world have purchased over 180 Giga Presses to imitate Tesla Credits to: Luca Greco #tesla #innovation #future

Affordable electric pickups? E-magy's nanoporous silicon could make them a reality. Last month I visited Ford Motor Company's historic Rouge plant as part of the NL Battery Mission to Detroit, and the scale of the F150 truck manufacturing operations there were hugely impressive, nevermind the history that is responsible for automotive production and the world's first affordable vehicles (Model T et al). It did highlight, however, with the number of ICE pickups still being made that we are missing a huge opportunity to electrify a vehicle class that the U.S. Department of Energy (DOE) identified this year as the one that most benefits from electrification - even more so than SUVs and vans! One current hurdle to this is the energy density of current Li-ion #battery cells, which cause these larger vehicle classes to be very heavy - reducing range, payload and towing capability - hence batteries E-magy's nanoporous silicon presents a solution, improving energy density and charge time! #OnWithSilicon

Mega/giga casting offers significant process simplification and - to use another buzzword - "decontenting" of a car body. All attractive to re-architect a new design into a cost-competitive production model. But it takes investment, plant overhaul and a learning curve. Journalist İlkhan Ozsevim explores the topic through the eyes of Volvo, Stellantis in contrast to the very public discussions concerning Tesla in this nice short article in Automotive Manufacturing Solutions #manufacturing #automotive #Tesla https://lnkd.in/e7EB98t4

Driving Innovation in Automotive Engineering with Zinger Vehicles Follow me for more technical insights: https://lnkd.in/evN3jc94 I’m excited to highlight the pioneering work happening at Zinger Vehicles, where we continuously push the boundaries of automotive design and engineering. Our latest accomplishment, the 21C’s Bio-Logic chassis, marks a significant advancement in vehicle technology. At Zinger Vehicles, Engineer for Pareto optimality at the full vehicle level. This means that every component of the 21C is meticulously optimized for peak performance. The chassis is designed to balance critical variables such as stiffness, fatigue, crash resilience, and manufacturing efficiency. This is achieved through in-house developed software suite, which harnesses AI and is implemented by a team of leading engineers. The 21C’s chassis represents cutting-edge manufacturing—produced additively using laser powder bed fusion and patented alloys, and robotically bonded with a precision of 0.1mm. This not only enhances vehicle performance and safety but also demonstrates Zinger Vehicles commitment to sustainability, as the chassis is 25% lighter than current industry standards. A special thanks to Mr. Lukas Czinger, President & CO of Divergent. #AutomotiveInnovation #Zinger21C #Automotivedesign

🚗 Exploring the Die Casting Process: AITO M9 vs. Tesla Model Y 🛠️ In the world of automotive manufacturing, innovation is key to delivering efficiency, performance, and quality. One such innovation that’s making waves is the die casting process, a method that has revolutionized the way car bodies are constructed. 🔍 AITO M9 vs. Tesla Model Y: AITO M9: The AITO M9 has embraced advanced giga casting methods to produce large body-in-white (BIW) components as single pieces, similar to Tesla’s approach. This method reduces the number of parts and welds, leading to enhanced structural integrity, weight reduction, and a streamlined assembly process. By integrating these large-scale casting techniques, AITO ensures that the M9 is both robust and efficient in its production. Tesla Model Y: Tesla’s Giga Press technology is a game-changer in the industry. By casting significant portions of the vehicle’s structure as single pieces, Tesla reduces complexity, boosts production speed, and improves the overall performance and safety of the Model Y. This approach leads to a lighter, more efficient vehicle with fewer points of potential failure. 🔧 Why It Matters: Structural Integrity: Both vehicles benefit from improved strength and safety due to fewer joints and connections, leading to more durable and reliable cars. Efficiency: These casting methods significantly reduce production time and costs, setting new standards for automotive manufacturing. Innovation: AITO and Tesla are leading the charge in transforming vehicle production, with giga casting representing a major leap forward in the industry. By adopting similar giga casting techniques, the AITO M9 and Tesla Model Y showcase the future of automotive manufacturing—a future where efficiency, strength, and innovation drive the industry forward. #AUTODATAS #GigaCasting #AutomotiveInnovation #TeslaModelY #AITOM9 #ManufacturingExcellence #AutomotiveBenchmarking #InnovationInMotion

What does the #Xiaomi SU7, the Tesla Model Y and the #Dodge RAM 1500 by Stellantis have in common? All are using either #GigaCastings or #GigaHotstampings in their body in white structure. Even though they´re made from different materials these large & complex body parts follow a similar philosophy: 💎 Key benefits: 👉 💲 reduced costs and complexity in OEM´s body shop 👉 🌲 Smaller CO² footprint through better material usage 👉 🚘 💥 🚓 Crash optimization #3DLaserCutting plays a crucial role in the production of Giga-Parts. With our #TruLaserCell8030 #TRUMPF offers not simply production cell but also its #Automation 🤖 🎮 for easy loading & unloading of these heavy parts. Big Thanks 🙏 to Thomas Ausmann for our interesting discussions about the Giga-Trends in Body in white 💪 Looking forward to see how this trend evolves. If you´re interested contact us at TRUMPF or leave a comment below 👇 #Laser #GigaCasting #GigaHotstamping #Automation