To make electric vehicles (EVs) cheaper and more efficient, automakers are exploring new manufacturing techniques like megacasting, or gigacasting, as Tesla calls it.

This method involves using large molds to cast parts from molten aluminum, streamlining production by reducing the number of components.

For instance, Tesla’s Model Y uses single-cast front and rear sections, unlike the Model 3’s multi-part design.

Major automakers like Toyota, Ford, and GM are also investing in this technology, which promises to reduce weight, cost, and complexity.

However, experts note challenges such as potential structural issues, higher scrap rates, and repair difficulties, CNBC has reported.

Tesla has scaled back plans to cast entire underbodies in one piece, suggesting technical hurdles. Despite the potential, the future of megacasting remains uncertain.

Written by B.C. Begley