Toyota Motor has demonstrated a prototype of its gigacasting equipment, a revolutionary technology set to transform electric vehicle (EV) manufacturing. This advanced machinery has the capability to create one-third of a car body in just three minutes, aiming to streamline production, reduce plant investment, and minimize manufacturing preparation lead times. Toyota’s goal is to sell 3.5 million EVs annually by 2030.
The gigacasting machine, located at Toyota’s Myochi plant in Japan, efficiently molds molten aluminum, converting it from 700°C to 250°C and forming a seamless die-cast piece that makes up the entire rear third of a vehicle chassis. This process replaces a complex and time-consuming 33-step process that required 86 separate parts.
Toyota’s objective is to halve production processes, reduce costs, and accelerate production readiness. The gigacasting technology will also extend to the front and rear sections of a new electric model expected to be released in 2026.
The journey into gigacasting technology began for Toyota in September 2022 with the construction of its first prototype. Over time, the company has significantly reduced the time it takes for part detachment during mold swapping, from a full day to just 20 minutes. Toyota aims to achieve a 20% higher productivity rate than its competitors, aided by proprietary software optimizing molding conditions.
In addition to gigacasting, Toyota has adopted a “self-propelled production” strategy for factory space efficiency. This strategy involves a partially assembled vehicle navigating towards a robot arm that attaches seats delivered by an automated guided vehicle. This setup allows for flexible plant layout changes and a 50% reduction in assembly time, as it eliminates the need for conveyor belts.
Toyota’s gigacasting technology and its commitment to innovation and efficiency position the company as a notable player in the competitive EV market. With a goal to sell 1.5 million EVs by 2026 and 3.5 million by 2030, Toyota aims to maintain profitability in the EV era. Their new frames will be employed in approximately 1.7 million of the 3.5 million EVs targeted for sale by 2030.
The adoption of gigacasting technology by Toyota, alongside its extensive automotive technology heritage and diverse model portfolio, showcases the company’s readiness to challenge the status quo in the EV market. As Tesla remains a dominant player in the industry, Toyota’s groundbreaking technology and rich automotive heritage position them as a strong contender in the competitive EV landscape.
Sources:
– Economic Times – https://auto.economictimes.indiatimes.com/Themes/Release/images/responsive/etauto-default.jpg
– Toyota’s Gigacasting Technology Advancement in EV Manufacturing – https://etimg.etb2bimg.com/photo/103786046.cms