Tesla's gigacast greatly reduces parts, welds and vehicle production time
Tesla
New insights into Tesla's manufacturing innovations have emerged, suggesting the automaker is not just nearing but actively implementing groundbreaking advancements in its gigacasting technology. Reports from the Shanghai Securities News and posts from X.com user @zhongwen2005 unveil Tesla's successful adoption of an upgraded gigacasting process at its Shanghai Giga Factory, focusing primarily on the Model Y's rear bottom plate assembly system.
This revelation is a pivotal update to earlier reports, indicating that Tesla is realizing its commitment to unboxed manufacturing and is on the brink of revolutionizing vehicle production. The upgraded gigacasting technology allows the die-casting of almost the entire complex underbody of an electric vehicle in one piece, significantly reducing production costs and assembly components.
New Technology Now in Use
According to the new information, the application of this integrated die-casting technology has led to a remarkable 40% reduction in related production costs and over 10% weight savings compared to traditional methods. These advancements are especially pertinent as Tesla explores manufacturing possibilities for its forthcoming $25,000 car, which presents an ideal opportunity to deploy this one-piece casting innovation.
Tesla's pioneering approach, involving 3D printing, industrial sand, and the development of specialized alloys, is further fine-tuned with the introduction of version 2.0 of its integrated die-casting technology. The amalgamation of rapid prototyping, material innovation, and advanced casting techniques underscores Tesla's relentless pursuit of manufacturing excellence, setting the stage for a large-scale manufacturing evolution.
This strategic shift and technological progression are aligned with the insights shared in Walter Isaacson's biography of Elon Musk, depicting a transition in Tesla's operational hubs. The Giga Texas facility emerges as a focal point for the development and perfection of this next-generation EV platform, with Giga Mexico anticipating the subsequent housing of the new technology.
The Competition is Playing Catch-up
As the electric vehicle market grows increasingly competitive, such innovations are crucial. The upgraded gigacasting technology places Tesla at the forefront of manufacturing efficiency and sets a precedent for other manufacturers. Toyota recently unveiled its own gigapress, and Chinese EV makers, including Xpeng and Geely's Zeekr, are adopting gigapressing technology to decrease vehicle weight and cut costs.
As Tesla continues to refine and implement its upgraded gigacasting technology, the company is not merely taking a step but making a significant leap toward redefining automotive manufacturing. The integration of this advanced technology at its Shanghai plant illustrates the tangible strides Tesla is making in realizing Elon Musk's vision of halving production costs and making electric vehicles more affordable and accessible.
The latest developments confirm that a transformative moment in EV manufacturing is not just on the horizon but actively unfolding. Tesla's commitment to innovation and the successful application of upgraded gigacasting technology underscore its position as a leader in the automotive industry, driving towards a future where electric vehicles are increasingly revolutionary and attainable.
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Tesla recently showed off Giga Small Haus, an interesting new display project hosted at Giga Berlin. The small new house is located just outside the main entrance of Tesla’s Giga Berlin factory, with a Quicksilver Model Y parked inside.
Giga Small Haus is powered only by solar and Powerwall 3 - disconnected from the local grid and from Giga Berlin itself. It serves as a live demonstration of Tesla Solar and Tesla’s Powerwall battery backup.
Giga Small Haus
The centerpiece of the display is a Model Y in Quicksilver - a beautiful pick for a beautifully lit house. However, that’s not the real focus here - it's the Powerwall and Gateway on the wall.
The Powerwall is the focus of Giga Small Haus, and there’s a display with some additional information on the wall. Part of the display also includes a screen that displays the current output of the Powerwall itself versus the consumption of Giga Small Haus, as well as the input from solar.
The interior exhibit of Giga Small Haus
Not a Tesla App
The text on the exhibit is divided into several sections. Here’s a translated and edited version of what we can see from Tesla’s images. Some additional text is obscured. If someone visits Giga Small Haus, let us know.
Powerwall
Powerwall is a home battery system that stores energy from solar panels, the electrical grid, or during off-peak hours and powers your home during the day or during a power outage.
With Powerwall, you can use self-generated solar energy during the day and night, thus avoiding high electricity costs. You can also store excess energy produced during sunny periods for use during times of low production or power outages.
Key Features
Energy Storage: Powerwall stores excess energy from solar panels or the grid for later use or during power outages.
Backup Power: In the event of a power outage, Powerwall automatically switches to battery power to ensure continuous power supply.
Integration: Powerwall can be seamlessly integrated with existing solar systems and other power sources.
Scalability: Multiple Powerwalls can be installed to meet higher energy storage needs.
Smart Energy Management: Powerwall works with Tesla's software to optimize energy consumption and reduce costs.
How Powerwall Works
Storage: During the day, when solar panels produce more energy than needed, the excess is stored in Powerwall.
Usage: At night or during times of low solar production, the stored energy is used to power the home, reducing reliance on the grid.
Backup: During a power outage, Powerwall automatically provides power to critical circuits, ensuring continuous operation of essential appliances.
Benefits
Cost Savings: By storing and using solar energy, you can reduce your electricity bills.
Reliability: Provides backup power during outages, ensuring your home remains powered.
Sustainability: Promotes the use of renewable energy by storing excess solar production for later use.
Overall, Giga Small Haus is an interesting real-life demo of what Powerwall and Solar can accomplish. It would be neat if Tesla built more of these displays - perhaps near major Delivery and Service Centers and at Giga Texas, Fremont, Giga Shanghai, and other facilities. Many Tesla owners have yet to learn about and experience some of Tesla’s Energy products.
Tesla has added the Acceleration Boost option to the Tesla store for owners of the 2024 Model 3 Long Range - specifically owners in Australia and China. Acceleration Boost is an upgrade that provides a significant performance boost, drastically narrowing the performance gap between the Long Range and Performance versions of the same model.
This upgrade will likely become available in Europe, Canada, and the United States in the next few days as Tesla updates its shops globally.
Acceleration Boost
This new Acceleration Boost is retailing for $3,000 AUD, or approximately $2,000 USD. That’s the same price for current owners of older Model 3 or Model Y Long Range vehicles, which all have the option to purchase Acceleration Boost through the shop.
The boost provides improved 0-100km/h (0-60mph) performance, bumping the 2024 Model 3 LR from 4.4s to 3.8s. The 2024 Performance version comes in at a blazing fast 2.9 seconds, so while it isn’t equivalent to just buying a performance variant in the first place, it is still a noticeable and significant upgrade.
Performance variants also come with a different front fascia vent for cooling, performance drive units, sport seats, adaptive suspension, 20-inch wheels, and Track Mode V3. That’s a significant number of additional features in the $10,000 USD price difference between the Long Range and Performance versions.
Should You Buy It?
If you’ve purchased a Long Range model and are itching to go just that little bit faster at every red light, this is the upgrade for you. It previously came with the cost of slightly reducing vehicle range, but the Tesla store doesn’t make a note of reduced range this time around. The 2023 Model 3 and Model Y Long Range models had an efficiency loss of about 5% due to the additional always-available acceleration and cooling.
You could drive in Chill mode to mostly negate that efficiency loss, but what’s the fun in driving in Chill when you just got Acceleration Boost? Anyhow, the shop listing for the 2024 variant doesn’t include this detail, so it's possible Tesla may have worked some more engineering magic.
Overall, if you’ve got the $3,000 AUD burning a hole in your pocket, some Tesla referral credits sitting around, or just want to go faster, it's definitely an upgrade many users find valuable.
