Markus Moll’s Post

Tesla’s Cybertruck: Where Power Meets Durability Tesla is redefining automotive innovation with the Cybertruck, crafted from a special grade of stainless steel that combines the strength and hardening rate of 301 with the corrosion resistance of 316L. This powerful blend offers strong durability and resilience for the future of electric vehicles. 🌍 Material Impact: • 125,000–250,000 units projected in 2025 • 140,000–170,000 tonnes of stainless steel (STS) required • +10% growth in the U.S. cold-rolled coil (CRC) market Material Composition: • Chrome: 16–18% • Nickel: 5–8% • Molybdenum: 1–2% The Cybertruck’s exoskeleton is not only bold in appearance but also built to withstand the toughest conditions, marking a shift in automotive manufacturing. 🔧 🌱 Sustainable. Strong. Smart. #Teslacybertruck #Electricvehicles #Stainlesssteel #Futureofmobility

And only one place to get this type of chrome growth and that is South Africa, with demand - supply already well balanced, any increase in demand will have to lead to higher prices to incentivise new investment, in mines and infrastructure, which remains the bottleneck of the South African chrome export industry

𝗚𝗜𝗚𝗔𝗖𝗔𝗦𝗧𝗜𝗡𝗚 𝐆𝐢𝐠𝐚𝐜𝐚𝐬𝐭𝐢𝐧𝐠 is a manufacturing process developed by Tesla, involving the use of large casting machines to create significant parts of a vehicle's structure in a single piece. This technique revolutionizes car manufacturing by streamlining production and reducing the number of components and assembly steps. Here's an in-depth look at Gigacasting, including its advantages and limitations: 𝐆𝐢𝐠𝐚𝐜𝐚𝐬𝐭𝐢𝐧𝐠 employs massive aluminium die-casting machines, which can produce large parts, such as entire front or rear vehicle underbodies, in one piece. The process involves: 𝘿𝙚𝙨𝙞𝙜𝙣 𝙖𝙣𝙙 𝙎𝙞𝙢𝙪𝙡𝙖𝙩𝙞𝙤𝙣: Advanced computer simulations to design parts that can be cast in a single piece. 𝘿𝙞𝙚 𝘾𝙖𝙨𝙩𝙞𝙣𝙜: Molten aluminium is injected into a mold at high pressure, filling the intricate design quickly and solidifying into a single, large part. 𝙋𝙤𝙨𝙩-𝙋𝙧𝙤𝙘𝙚𝙨𝙨𝙞𝙣𝙜: The cast part undergoes trimming, machining and other finishing processes to meet precise specifications. 💠 𝘼𝙙𝙫𝙖𝙣𝙩𝙖𝙜𝙚𝙨: 👉 Reduced Complexity 👉 Improved Structural Integrity 👉 Design Flexibility 👉 Weight Reduction 👉 Fast Production Speed 👉 Cost Savings 💠 𝙇𝙞𝙢𝙞𝙩𝙖𝙩𝙞𝙤𝙣𝙨: 👉 High Initial Investment 👉 Technical Challenges 👉 Material Constraints 👉 Tooling and Maintenance 👉 Flexibility Issues 👉 Heat Management 💠 𝐂𝐨𝐦𝐩𝐚𝐧𝐢𝐞𝐬 𝐰𝐨𝐫𝐤𝐢𝐧𝐠 𝐨𝐧 𝐆𝐢𝐠𝐚𝐜𝐚𝐬𝐭𝐢𝐧𝐠: ➡ Tesla ➡ Toyota Motor Corporation ➡ General Motors ➡ Hyundai Motor Company (현대자동차) ➡ Volvo Cars ➡ XPENG ➡ Zeekr Europe ➡ NIO ➡ Huawei ➡ Baic #Gigacasting #Automobile #ElectricVehicles #EVManufacturing #TeslaInnovation #AutoRevolution #FutureOfAutomotive #SustainableMobility #GreenManufacturing #GreenTech #GreenMobility #ZeroEmissions

Add ‘Magnets’ to the List of Things That Damage the Tesla Cybertruck Be careful what you stick to stainless steel; it may not stay that way. A Tesla Cybertruck owner who used a sheet magnet to promote their personal business found out the hard way that stainless steel may not stay so stainless when you cover it in certain materials. Upon removing the magnet after a month on the vehicle, the owner discovered not only superficial scratches from debris, but signs of full-blown galvanic corrosion. In this case, the corrosion progressed to the point where the Cybertruck’s stainless-steel body actually appears to have pitted. The short version is this: You shouldn’t stick metallic magnets on your Tesla Cybertruck. In fact, according to one participant in the discussion associated with a company that is developing outer panel covers for the stainless-steel pickup, it’s not wise to leave anything on the Cybertruck permanently, especially if the surface wasn’t thoroughly cleaned and prepped first. https://lnkd.in/dHJpcXe6

 Tesla Cybertruck Faces a Metallic Challenge! 🛻⚡ In a surprising twist, the much-anticipated Tesla Cybertruck, known for its stainless steel exoskeleton, has been reported to experience extensive corrosion after exposure to a magnet under certain conditions. 🧲⚠️ This incident raises questions about the durability and resilience of its futuristic design, marketed as nearly indestructible. While stainless steel is resistant to rust, environmental factors and magnetic interactions may create unforeseen challenges. Tesla has yet to issue a formal statement, but this situation highlights the importance of rigorous testing for groundbreaking technologies before mass deployment. Could this be a minor hiccup or a sign of a larger material oversight? Share your thoughts below! 🛠️ #TeslaCybertruck #InnovationChallenges #EVTech #MaterialScience

🚗 Giga Casting: Revolutionizing Electric Cars, One Large Component at a Time 🚗 Giga casting is transforming the automotive industry by enabling the production of large, single-piece components that reduce weight, assembly time, and costs. However, such innovation comes with its own set of challenges: 🔧 Material Flow Issues: Ensuring uniform mold filling to avoid cold shuts or incomplete components. 🔥 Thermal Management: Large components retain significant heat, requiring precise cooling control. Uneven cooling can lead to thermal stresses, warping, or cracking. ⚠️ Defects: Shrinkage, porosity, gas entrapment, and other structural flaws that compromise quality. 💰 High Tooling Costs: Expensive mold design and maintenance, leaving little room for error. ⚙️ Production Complexity: Advanced machinery and precise control are essential for large-scale manufacturing. 📏 Quality Assurance: Ensuring defect-free, consistent quality across large parts is a major challenge. This is where FLOW-3D CAST steps in as the ultimate solution: ✅ Simulate Material Flow: Predict how molten metal behaves in the mold for uniform filling. ✅ Defect Prevention: Identify shrinkage, porosity, and thermal stresses before production begins. ✅ Thermal Optimization: Model heat transfer and cooling to prevent warping or cracking. ✅ Cost Efficiency: Reduce trial-and-error, minimize waste, and optimize production processes. Leading automakers like Tesla, BMW, Toyota, Stellantis, NIO, Daimler, Dongfeng Motor Corporation, and Audi trust FLOW-3D CAST to overcome these challenges and achieve exceptional results in giga casting. 🚀 Ready to transform your casting process? Let’s connect and explore how FLOW-3D CAST can help! In this video, we see the filling process of an electric-vehicle rear-underbody using "FLOW-3D CAST". The part is made of A319 LM4 aluminum alloy, which is poured at temperature of 640 degrees and velocity of 4 m/s. This kind of automotive components is typically divided into several subcomponents, which get assembled together later to form a complete part. With Giga casting presses, it is now possible to manufacture this part as a whole, single piece, in less than two minutes. "FLOW-3D CAST" can boost the design process and anticipate the problematic areas before bringing the design into reality. #elrefay #HPDC #GigaCasting #FLOW3DCAST #ElectricVehicles #AutomotiveInnovation #CastingSimulation #Efficiency #FLOW3D #cfd #arabworld

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