中文
Subsequently, when Lei Jun announced the Xiaomi Million Dollar Annual Technology Award, "Xiaomi's surging OS architecture" and "integrated die-casting technology" were both awarded, indicating Xiaomi's favor for this technology.
A few months later, Tesla, located far across the Pacific, was exposed by the media as giving up on the next generation of integrated casting. After the news spread to China, a group of new power car companies fell into contemplation.
In the biography of Musk, there is a chapter called "Super Casting" which states that Tesla's integrated die-casting technology originated from Musk's random disassembly of a car model, ultimately causing a global revolution in automotive technology.
Although the description may have a refreshing online feel, since Tesla announced in September 2020 that the Model Y will adopt integrated die-casting production for the rear body and floor assembly, as well as promoting the use of this technology in other models of the brand, global car companies have quickly followed suit, such as domestic new force car companies NIO, Xiaopeng, Gaohe, Jike, etc.
It is undeniable that integrated die-casting technology does have its own uniqueness.
As Tesla has stated, this process can accelerate car manufacturing speed and significantly reduce costs. The data shows that using the Model Y integrated die cast rear bottom plate assembly, the total weight of the rear bottom plate is reduced by 30%, and the overall manufacturing cost of the vehicle is reduced by 40%.
More importantly, thanks to the support of integrated die-casting technology, Tesla can develop a new car in just 18-24 months, while during the same period, most car companies took more than 3 years to develop new cars. It is worth mentioning that Musk proposed the "Integrated Die Casting 2.0" or unboxing process at Tesla Investment Day in 2023.
This process technology will no longer completely follow traditional manufacturing processes such as stamping, welding, etc., and can be used to assemble cars like LEGO. At that time, Tesla stated that through this "ultimate technology", it could reduce factory manufacturing personnel by 40%, reduce manufacturing space and time by 30%, and assembly costs were only half of the current Model 3 and Model Y.
It has to be said that in the car market where price wars continue, every penny saved by car companies may become the key to victory, and even the hope of survival. The incredible integrated die-casting technology depicted by Musk has become a must-have for new car manufacturers.
When it comes to imitating Tesla's "integrated die-casting", Xiaomi and Celes are definitely among the best among many car companies.
Lei Jun once stated that Tesla's latest completed factory is 9000 tons, and Xiaomi's self-designed integrated die-casting process system (9100 tons) has surpassed Tesla.
Leading by a long distance, becoming an evaluation of Xiaomi's integrated die-casting technology by netizens. However, the arms war of integrated die-casting has just begun.
Xiaomi's "super large die-casting" became the first in less than 48 hours. At the Xiaopeng press conference, it was announced that the Xiaopeng X9 will use 12000 ton integrated die-casting, and there are rumors that Xiaopeng is installing 16000 ton die-casting units. In addition, Nezha Automobile announced that it will collaborate with Lijin Group to jointly develop a 20000 ton integrated die-casting machine.
The continuous increase in tonnage shows the car companies' admiration and craziness for integrated die-casting technology. However, it is worrisome that Tesla, which once vigorously promoted integrated die-casting, suddenly "withdrew" in the face of multiple global car companies following suit, seemingly indicating a defect in the technology.
From a process perspective, the error of die-casting parts is difficult to match that of stamped parts.
For example, the standard for Volkswagen stamping parts is ± 0.5mm, or even ± 0.2mm, which is a level that is difficult to compare with castings. It is worth mentioning that the larger the casting, the greater the deviation. In addition to accuracy issues, castings also need to undergo heat treatment after casting. After thermal expansion and contraction, the already difficult to control accuracy issues become more severe.
Due to accuracy issues, approximately 60% of the casting waste was once placed on the empty ground of the German Glenhead factory in cooperation with Tesla. In the end, it took Tesla a year to increase the yield rate of integrated die-casting flooring from 30% to around 85%, and the entire improvement process involved material and other dimensions.
Despite the increase in yield rate, there are still many issues plaguing Tesla, such as ensuring stable sales. Behind Musk's advocacy for a 40% cost reduction in integrated die-casting technology, it largely depends on the huge shipment volume.
The data shows that the cost of body parts made of C611 magnesium aluminum alloy in integrated die casting is as high as 40 yuan, which is about twice that of steel body parts. It is estimated that in order to ensure the cost-effectiveness of the die-casting machine, a monthly production of 15000 pieces is required, which means an annual sales volume of 180000 vehicles.
From the perspective of efficiency and other factors, integrated die-casting is indeed a rare technology for car companies with high sales. However, based on the 2023 New Power Car Company Sales Ranking, only Ideal is the car company with annual sales reaching the "standard".
Looking at a group of new power car companies, there are many players who are "long-term oriented". However, from the perspective of initial investment, the high cost of integrated die-casting technology is equivalent to a huge sunk cost for start-up car companies. According to estimates from institutions, a 9000 ton level die-casting machine is priced at up to 90 million yuan, with an average of 10000 yuan per ton. However, Xiaopeng and Nezha's die-casting machines, which often cost tens of thousands of tons, have a relatively high cost.
In addition, CICC Securities has calculated that under the premise of producing 100000 vehicles annually, the total investment in equipment using traditional stamping welding technology is about 520 million yuan, and the total investment in equipment using integrated technology is as high as 710 million yuan. Interestingly, the Tesla Model 3 has not yet been included in the integrated die-casting queue.
The crazy "tonnage war" and the overlapping "internal competition" in the car market have made new force car companies seem to have become eye-catching, ignoring Tesla's efficient cost reduction, which stems from the huge shipment volume. Unfortunately, the car companies that have only recently awakened are already deeply mired in the mud.
Integrated die-casting is undoubtedly a double-edged sword for car companies. For car companies that have already achieved economies of scale, it is the icing on the cake. However, for car companies whose sales have not yet undergone a qualitative change, besides briefly improving brand power, it is more of a huge cost of silence. At this point, car companies that have not yet followed up need to think carefully when facing integrated die-casting technology.
