Toyota Embraces Tesla-Style Gigacasting for EV Production

Toyota is set to test a massive gigacasting machine at its Japanese plant, adopting a technique pioneered by Tesla to streamline electric vehicle (EV) production and reduce costs. This move signals Toyota’s commitment to advancing its EV manufacturing capabilities, according to a report from Nikkei Asia.

Giant Machine, Big Ambitions

The Japanese automaker plans to install a gigacasting machine at its production center in Aichi prefecture as early as this year. This behemoth, manufactured by Ube Machinery, will be one of Japan’s largest casting machines, capable of exerting 9,000 tonnes of clamping pressure.

“Gigacasting involves creating large modules for vehicles by fusing multiple components together using molten aluminum alloy that is fed into a molding machine at high pressure,” the report explains. This process allows for significant reductions in vehicle mass and improved production efficiency.

The Lexus Connection

Toyota’s foray into gigacasting technology will debut with the Lexus LF-ZC, a next-generation EV slated for release in 2026. The automaker has already achieved impressive results in prototype testing, combining 86 parts and 33 processes into a single module for the vehicle’s rear portion.

Catching Up to Global Competition

While Toyota is making strides, it’s playing catch-up in the gigacasting arena. Tesla, the pioneer of this technology, already employs gigapresses with 6,000 to 9,000 tonnes of clamping force in its production lines. Other Japanese automakers are also in the race, with Honda rolling out a 6,000-tonne machine and Nissan planning to install one by fiscal 2027.

EVXL’s Take

Toyota’s adoption of gigacasting technology marks a significant step in its EV strategy. This move aligns with the broader industry trend of streamlining EV production to achieve cost parity with traditional vehicles. As we’ve seen with Tesla’s success, innovative manufacturing techniques can be a game-changer in the EV market. Toyota’s investment in this technology could potentially accelerate its EV rollout and improve its competitiveness in the rapidly evolving electric vehicle landscape.

Photo courtesy of Toyota / Lexus