Which casting method do you think Tesla will select? And will this new large Gigacasting interfere with Tesla’s Unboxed Process or is there a middle ground they can go with? Be sure to watch: • ELON MUSK: A Great Reckoning Is Coming: ua-cam.com/video/MLpwow40bPM/v-deo.html • Major New Tesla Sodium-Ion Battery Breakthrough: ua-cam.com/video/zfwFyImuuDc/v-deo.html Visit our website: themarketisopen.com for instant stock quotes and free financial data
Single cast is a misunderstanding by Reuters. (Imo) Think it through. You make a single casting. Presumably, you want structural cells in the pack? You either have to assemble the cells directly into that casting, or build a separate unit... Which defeats the object? . If you DO assemble the cells directly you must then stack *the whole casting* while you test the pack. That's a huge amount of space.... which defeats the object(!) and if there's an issue, you must recycle the whole casting (body) to the previous point, remove and refit new cells. (Not to mention cell/ pack replacement as a service operation) Then there's the "interior build onto pack" issue. You would still have to get the interior inside the passenger cage. How? If you build it on top of the pack then insert it from underneath.... That what they do now and what the unboxed system would involve, so why change? Otherwise, you're back to working inside the vehicle... The old method. . It's far more logical, space and worker efficient to take "a casting" say the front section, bolt on suspension, bodywork, cooling, control, and other systems working on 4 sides then transport to the assembly point, meeting 3 other *complete* sections and marry the units.
I'm pretty sure that the Cybertruck underbody is structural. So is the body, to a point. But the main point of using the word 'exoskeleton' for Cybertruck is this: the tough part is on the outside. Paint and sheet metal aluminum isn't tough. 3 mil stainless steel is. I suspect that a single casting for the underbody is significant, but not as significant as using stainless steel in the next-gen body. Imagine an affordable car that is immune to cart demons and parking lot dings. Think that will sell? With Tesla's software and connectivity? With good performance and range? Demand will be insane.
They could use a Disamatic moulding machine which allows the use of cores. It has a cycle time of 10 seconds and the casting is cooled in the sand mould outside the moulding machine
I know you want comments, but asking us which casting method Elon should choose... well... I'll go with whatever method Elon decides. :) But I do appreciate the energy and effort you put into your videos... very well done.
16,000 Ton die casting machine wow. I am an ex casting engineer at a Japanese car company. At my place, casting parts are cast on a 1650 die casting machine Tons, mostly used in car engines and under the responsibility of the engine group. Meanwhile, the body group is responsible for the inside of the car body. With Tesla's courage and great success in redesigning the car body, there is no doubt that all car manufacturers will follow suit in the next few years. This could provide benefits to casting engineers wherever they are, as their needs will double or triple in the automotive industry.
I thought it was at least the rear casting for quite some time. www.tesmanian.com/blogs/tesmanian-blog/tesla-to-produce-model-3-with-rear-single-piece-casts-using-parts-from-gasoline-cars
Excellent presentation of the in depth Reuters article. Well done. This is really new stuff even for Tesla. Sounds of silence from Tesla means there’s a whole lotta thinking goin on.
Some very good observations regarding the single piece chassis construction and manufacturing challenges, as well as potential benefits. I'm guessing we'll see the unboxed assembly used with three sections for the larger vehicles, and maybe a one piece hybrid with the top of the battery pack including seats as an assembly for a sub compact. Thanks!
The sand core method may apply only to casting the press dies before machining, An alternative is jet printing which also can produce complex internal passages. This is a regular required process as the injection molds wear out. Injection filling such a complex and large total frame mold may not be as quick as it can fill the current end castings, hence a different alloy. Final assembly interior details for the single die-cast car structure will be aided by accessibility from the large bottom battery hole before the complete with-seats structural battery is inserted. Confusion in reporting without understanding is what I think we are hearing.
You would case the piece ahead of time and have the battery and all the components attached to the casting assembled in a different place so that it would act as its own module. This would allow for the worker to have easy access for assembly.
The unboxed process could still be used, even with a vehicle where the entire subframe is one gigantic casting. The vehicle could be divided between top and bottom, with the top inverted or set on its side in a support frame. Then the two halves could be joined near the last assembly step.
Meanwhile, you seem to think that the engineers and designers have brought in this monstrous, multimillion dollar press without any thought as to how it will affect the overall production process. Such oblivious arrogance will cause me to read less and less of what you produce. First, you think you understand the existing process. Starting from that state of ignorance then leads us to complete incoherence on any further changes.
Tesla does not create or manufacture the Giga Press. It is built by an Italian/Chinese firm called Idra. There are about 20 of the Idra presses shipped so far, and Tesla has the most of them. It's a killer machine, and weighs so much you have to build a special floor to hold it. The cycle time is incredibly fast.
Everyone knows Musk asked a few companies to make the giga press and only Idra said ok/maybe it's possible. It wouldn't exist if not for Tesla and Idra. Now, like iPhone, everyone else is following.
@@newdrew2744"Idra" just an Italian name for a Chinese manufacturer. You have to ask yourself how much money you want to give China. Tesla has built his company on tooling and products, "dumped" undervalue from China. Laborers in the United States have become the cheap labor that used to be what was outsourced to other countries. With Teslas union busting history, firing anyone that have any interest in starting a union at a Tesla facility. There's a reason thousands of people are willing to put their jobs on the line, not only for themselves but for all workers to earn a fair wage.
@@paul5683every now and then I wonder what problems there are in reading before making statements: IDRA Presse founded in 1946 by Adamo Pasotti in Brescia in 2008 taken over by L.K. Tecnology Holding ltd: this is not a fake Italian company invented by the Chinese, apparently it is a company in which they thought it was worth putting their money.
I am very confused with this report of a single casting for the bottom. The bottom is literally the structural battery pack, and the front and rear casting are the remainder of the bottom. Making those one piece would greatly complicate the battery assembly. I could see the cast be the front, back, and sides, as the top has no cross structure.
That's what it is and what the design patent shows. I think the bottom casting is a Reuters story to throw people off. Nothing they say about tesla&tsla can be trusted imo. 👍🏻
Tesla can combine the priciples of the unboxed process with gigacasting 2.0. We did see lately in the video from a trade show how they design sub assemlies in the front and rear to be fitted in one direction only. This makes it easier to use optimus robots and cuts down on assembly time. Nothing would stop them to use this methods if the gigacasting of the skate board would be done in one piece. This is entirely possible with small design changes to the Idra press. Just imagine a machine using platens twice the size of the 9,000 ton press side by side. It would have two toggle mechanisms for closing/clamping and six tie bars. Beside the platen size which would extend the horizontal dimension two fold, the components of the machine would be largely the same.
It's a contradiction. The whole point of unboxed is to work on 4 sides of a unit then bolt the units together. Assuming 3 units, that's 12 "workers" total simultaneously. The single casting is a retrograde set back to 4.
Tesla has perfected the production line so that it’s innovative, efficient and upgradable so that the process is self sustaining. The next big item is Automation of driving, this will change the motor industry. Tesla will achieve the manufacturing to such a point that they are years ahead of the competition. The next big step for the brand is providing an effective, efficient means of generating electric its storage giving the freedom / independence of not needing the grid as a supplier. This market is much bigger than the car, truck industry.
I wonder why the never tried reorienting the horizontal giga press vertically. Reduce the ram sets required to one and getting a gravity assist, reducing the ram sizes whilst still getting full clamping pressure.
@@GT4viper Great point. What I'm thinking about is that the lower half of the die base is fixed, requiring no rams. The upper die rams only require the target clamping force minus the mass of the moveable ram assembly. Something like a drop forge design modified into a die casting forge. A search of "largest drop forge" returns plans for machines that generate 40,000 tons of clamping force. "[...With a new concept for the design and construction, Siempelkamp made it possible to bring together practically incompatible customer requirements in a single solution. The design is a four-column under-floor press with external main cylinders and hydraulic parallelism control, to compensate for the diverse vertical expansions associated with the eccentric stresses. It permits the production of high-tech drop-forged parts more safely and reliably, even faster than before, and at lower cost. The press weighs approximately 5,350 metric tons, due to the heavy-duty design of the press frame, in order to provide the rigidity required. The moving mass of the upper moving cross-head alone weighs 2,550 metric tons, and the upper die can add up to 200 metric tons. Thanks to the design of the cylinder heads, the four main cylinders are highly durable. The design provides a guarantee for 10 million full-load strokes...]"
"Tesla has been making use of large gigacasting...for model 3 and Y" @ 1:32 That statement is not quite correct, Y is using gigacastings but 3 has not, there is no report that show they are using it for Highland Model 3 yet AFAIK
Yeah I think just the rear of the Model 3 at least was using the Giga casting: www.tesmanian.com/blogs/tesmanian-blog/tesla-to-produce-model-3-with-rear-single-piece-casts-using-parts-from-gasoline-cars Though this article here appears to say it's both. Article might be wrong though. www.designnews.com/automotive-engineering/teslas-switch-giga-press-die-castings-model-3-eliminates-370-parts
Why not use that sand method for creating the steel molds that are made from the CNC method? Instead of taking months to grid down a single block of steel for the desired part it could be cast and fine tuned.
So what happens when you have an accident and smash the front end of your Tesla? It's all one piece. Can't just replace a fender. Insurance companies will just love the costs of repairs.
I'd go with both casting methods. Separate the factories and models and teams into the two methods, then have them compete. Over time one method will likely show a clear advantage, and in the mean time developing both methods will result in a lot of new knowledge.
At lab scale, yes. But at factory scale, too expensive. You will have 50% loss cost at the end. Inside one team you can do A/B development, but cross-checking frequently on smaller outcomes moving the whole process forward more efficiently.
You can't do both. The cost at putting one of these online is in the millions. Besides, that 4-way casting machine is an impossibility..... running one is hard enough, and now you need 4 to run at millisecond precision with all 4 having perfect shot profiles? Not a chance.
Interesting topic.I am assuming that 12KT Giga Press will be bigger heavier than 6KT press but it many not not be double the cost. It will be cheaper to produce one piece sub-frame in one machine instead of two pieces in two machines. Let that sink in!
the new single casting could be a casting for the upper car structure which would be added after the 3 unboxed pieces have came together. It could cast both the right & left door frame & roof structure as 1 piece instead of the current sheet metal pressed pieces.
tESLA does not make the gigapress. It is made in italy Italy The Giga Press program is a series of aluminium die casting machines manufactured for Tesla, initially by Idra Group in Italy. Idra presses were the largest high-pressure die casting machines in production as of 2020, with a clamping force of 55,000 to 61,000 kilonewtons (5,600 to 6,200 tf). They do not make them please make the correction.
Ok, that’s it. I’m supporting this channel. This subject is above my pay grade and outside my AOE, so all I can do is marvel at the pace of innovation. Not to mention your research, info and presentation prowess, and for having a financial background, your understanding of physics and engineering concepts are incredible. Thx for all the hard work.
The Unbox method will require precise timing driven by software. Software is where Tesla excels. Once perfected this method will put the competition at a huge disadvantage as production cost will go way down with the Unbox process.
Elons decision in giving users access to FSD was a great move, not only will it be bought by people but also the amount of data being collected by road users would of had a great impact. More data more the AI learns to drive
Die casting is a maintenance heavy manufacturing process. You are right, the special grease they use is high molybdenum goo. The actual steel tool needs to be torn down, cleaned, repaired and reassembled on a fairly regular basis. If not, preventive maintenance like that soon turns to major repairs. Things like an ejector pin getting bent. When they get bent, the bent pin starts to screw up the precision hole that it runs in, then the casting starts flashing really bad around the hole, then the flashing will push down into the hole, further screwing up the hole. It all goes to he'll in a big hurry and some robot isn't going to be able to keep it from happening. This brings the fact that they will need multiple molds of the same product because production can't rely on one tool. Like the guy in the video said, these are multi million dollar molds. The trouble is that these are along with most of the Tesla tooling, "dumped " Chinese products. Yes, "dumped " Chinese products, they have been doing that shit for decades and Tesla is benefiting from that "dumped "resource.
The best path forward is likely a few pieces. It is to be commended that Elon is exploring casting techniques and alloys. There should be great benefits to properly developed techniques. It was not so many years ago Semi- solid casting techniques were developed. I don’t agree with your assertion that sand casting is useful for rapid development since the grain structure is completely different.
I wonder what the throughput difference in ‘slow injection’ vs ‘fast injection’ casting really are? Fast injection is required to avoid imperfections, voids, in the casting. Chasing alloys and mold design helps here; it could be that this is why the rapid and low-cost prototyping of the sand casting is being explored-for casting quality-lowering fault rates (very) expensive parts loss.
It’s the same methods as ship builders use: modular components assembled at a: “marrying” location. Minimizing sub assemblies, by having larger main components joined together at a final location. Ship builders have been doing this for several years. Nothing new here.
The question I don’t hear anyone asking is what happens to a cast car frame in a crash, and what the repair process would look like. Stamped/welded frames tend to bend rather than crack, and can be straightened again. Will cast frames do the same, or will the castings be more likely to crack instead of bend. If that happens, how do you repair them? Can you use welding to repair cracked castings without compromising strength? I have no idea of the answers to these questions, but I don’t understand why no one is asking or talking about them. (Maybe my gut is wrong and it’s just a complete non-issue?)
Depends where it went bend/damage, but yes, once they crunch enough they're done unlike other cars that you might be able to tapper out again. Problem is - this saves so much time and money in the purchase side - that - this wont change from a mfg. side of things. Its no different than when you phone breaks. Live in a throw away world - but "cost" is the main driving force into why we do.
So what happens after a car accident and repairs need to be made? Do they have to replace the whole “Giga panel?” Sounds like any repair would be quite expensive, and it would be easier to consider it a total loss.
Two gigapresses operating at the same time vs one big one? It seems to be a diminishing return. Removing one part doesn't seem advantageous, especially if it reduces efficiency by forcing linear manufacturing. Having said that, Elon is the man who is most qualified to know the best way to go.
@@TMIOTesla Another is the fact you can work with two pieces though - if there is an issue with one side - you have to recast vs just garbing another part. Aka, you do loose the ability to repair as well to some level as now you have to fix the whole thing - vs just a section.
I guess the service & repair cost will go higher since they will need to change the whole cast piece than the small part that is damaged...congratulation EV´s fans.
I mean I get that more you can press the less over all parts you have to put togather, but isnt there a point that it doesnt matter? I mean sure you get to skip a step, but the time to do that step vs the time you have to press the whole thing I would think wouldnt make that much of a differenc I wouldnt think.
It's a good point. I was thinking about that too. It looks liek Tesla still needs to design what works best, given the Unboxes Process. But if they go with Giant casting press, that could save cost and floor space and even speed, versus say 2 large casting machines and a series of robots that need to weld the parts together.
First off the plastic modeling companies have been doing this for almost 100 years (yes I realize not apples to oranges). Secondly it's not a Tesla press. The press is the genius creation and engineering wonder of IDRA Group an Italian company.
Manufacturing cost savings will be huge. The problem I see if this vehicle gets into an accident, the higher probability of the vehicle being totaled because of the damage done to an exoskeleton. This could result in higher insurance premiums. Higher cost of ownership.
This Giga technology provides an advantage for the vehicle assembly process by casting larger components. The shortfall is the exorbitant cost of the tooling and multiple revisions. Even if this cost can be reduced, maintenance becomes a nightmare. Small damage to the part via accident will require a major "component replacement." This cost is hidden from the consumer in terms of premium insurance. Now, we know why Tesla's car insurance is at least twice the regular rate for traditional cars. The Chinese won't probably adopt this option.
The giga press idea was amazing truly revolutionary the pick up truck they make is garbage. It’s going to go nowhere fast, but this technology may help reduce the cost of their other vehicles. Of course it comes with its own issues because now insurance rates for these vehicles go up because a tiny bump to the rear totals out the whole vehicle. That’s not a problem for the manufacturer necessarily, but customers might not like the higher insurance rate.
Let me get this straight: Tesla/Musk owned Space X regularly wasted entire collections of multi million dollar boosters in development and you think they’re worried or would be concerned about a $1.5 million press.😂😂😂
Car manufacturers should stand their ground and offer consumers cheap, simple, easy-to-repair, basic cars. If consumers had the opportunity to buy such ready-made Tesla Gigapress car bodies with a variety of low-power internal combustion engines, for example. Koenigsegg Quark Motor,- without any fault-prone HI-tec technology, I believe that the trade would go at a completely different pace.
We should not accept mass production of goods such as the Structural battery, its does not allow for cost effective recycling. It’s either good or bad unlike previous modular batteries which could be repurposed as power storage, be it less capacity but lives onto to an extended life. And with all this cost saving, I’ve yet to see the price of Tesla come down. Tesla also seems to escape the consumer demand for a new model or refresh each year.
Great Only problem is the worlds' Electrical grids are Barely able to meet existing Demands. Imagine what adding on a Million (or More ) EVs charging needs ... will cause
Which casting method do you think Tesla will select? And will this new large Gigacasting interfere with Tesla’s Unboxed Process or is there a middle ground they can go with? Be sure to watch:
• ELON MUSK: A Great Reckoning Is Coming: ua-cam.com/video/MLpwow40bPM/v-deo.html
• Major New Tesla Sodium-Ion Battery Breakthrough: ua-cam.com/video/zfwFyImuuDc/v-deo.html
Visit our website: themarketisopen.com for instant stock quotes and free financial data
Cast the entire bottom and box the top parts.
Single cast is a misunderstanding by Reuters. (Imo)
Think it through.
You make a single casting.
Presumably, you want structural cells in the pack?
You either have to assemble the cells directly into that casting, or build a separate unit... Which defeats the object?
.
If you DO assemble the cells directly you must then stack *the whole casting* while you test the pack. That's a huge amount of space.... which defeats the object(!) and if there's an issue, you must recycle the whole casting (body) to the previous point, remove and refit new cells.
(Not to mention cell/ pack replacement as a service operation)
Then there's the "interior build onto pack" issue.
You would still have to get the interior inside the passenger cage. How?
If you build it on top of the pack then insert it from underneath.... That what they do now and what the unboxed system would involve, so why change?
Otherwise, you're back to working inside the vehicle... The old method.
.
It's far more logical, space and worker efficient to take "a casting" say the front section, bolt on suspension, bodywork, cooling, control, and other systems working on 4 sides then transport to the assembly point, meeting 3 other *complete* sections and marry the units.
The slower method as it has a quicker turnaround in development and you can always run multiple presses to increase production
I thought Sandy Monroe said the Cybertruck was not going to be an exoskeleton after seeing what was underneath.
Tesla's insane cashflow and cash reserves are really starting to shine.
I'm pretty sure that the Cybertruck underbody is structural.
So is the body, to a point. But the main point of using the word 'exoskeleton' for Cybertruck is this: the tough part is on the outside. Paint and sheet metal aluminum isn't tough. 3 mil stainless steel is.
I suspect that a single casting for the underbody is significant, but not as significant as using stainless steel in the next-gen body. Imagine an affordable car that is immune to cart demons and parking lot dings. Think that will sell? With Tesla's software and connectivity? With good performance and range?
Demand will be insane.
While everyone else is focused on the Isaacson bio, you nailed this huge casting news. Awesome explainer!
Basically a life size Hot Wheels!! 😊👍
They could use a Disamatic moulding machine which allows the use of cores. It has a cycle time of 10 seconds and the casting is cooled in the sand mould outside the moulding machine
Those cores would have to be carefully supported and preheated to keep them from shutting off the filling process before all parts were filled.
I know you want comments, but asking us which casting method Elon should choose... well... I'll go with whatever method Elon decides. :) But I do appreciate the energy and effort you put into your videos... very well done.
16,000 Ton die casting machine wow.
I am an ex casting engineer at a Japanese car company. At my place, casting parts are cast on a 1650 die casting machine
Tons, mostly used in car engines and under the responsibility of the engine group.
Meanwhile, the body group is responsible for the inside of the car body.
With Tesla's courage and great success in redesigning the car body, there is no doubt that all car manufacturers will follow suit in the next few years.
This could provide benefits to casting engineers wherever they are, as their needs will double or triple in the automotive industry.
I am fairly certain gigacastings are not being used on the model 3. 1:30
I thought it was at least the rear casting for quite some time.
www.tesmanian.com/blogs/tesmanian-blog/tesla-to-produce-model-3-with-rear-single-piece-casts-using-parts-from-gasoline-cars
@@TMIOTesla oh, I didn’t realize that. Thank you.
That was really good. I'm amazed that those machines. It's all pretty fascinating
Excellent presentation of the in depth Reuters article. Well done. This is really new stuff even for Tesla. Sounds of silence from Tesla means there’s a whole lotta thinking goin on.
Think baby think
Some very good observations regarding the single piece chassis construction and manufacturing challenges, as well as potential benefits. I'm guessing we'll see the unboxed assembly used with three sections for the larger vehicles, and maybe a one piece hybrid with the top of the battery pack including seats as an assembly for a sub compact. Thanks!
The sand core method may apply only to casting the press dies before machining, An alternative is jet printing which also can produce complex internal passages. This is a regular required process as the injection molds wear out.
Injection filling such a complex and large total frame mold may not be as quick as it can fill the current end castings, hence a different alloy.
Final assembly interior details for the single die-cast car structure will be aided by accessibility from the large bottom battery hole before the complete with-seats structural battery is inserted.
Confusion in reporting without understanding is what I think we are hearing.
You would case the piece ahead of time and have the battery and all the components attached to the casting assembled in a different place so that it would act as its own module. This would allow for the worker to have easy access for assembly.
No car company in the States move as fast as Tesla. The big 3 cars stay broken for years or until parts suppliers contracts expire.
The unboxed process could still be used, even with a vehicle where the entire subframe is one gigantic casting. The vehicle could be divided between top and bottom, with the top inverted or set on its side in a support frame. Then the two halves could be joined near the last assembly step.
It's a complete contradiction of the unboxed process.
Meanwhile, you seem to think that the engineers and designers have brought in this monstrous, multimillion dollar press without any thought as to how it will affect the overall production process. Such oblivious arrogance will cause me to read less and less of what you produce.
First, you think you understand the existing process. Starting from that state of ignorance then leads us to complete incoherence on any further changes.
What happens if you have a crash and need to replace something. Is the car written off as you need to change half the car?
Clearly the effort you put into these vlogs is second none, very much appreciated 👍👏👏👏👏👏👏👏
Thanks!
Thank you!
Tesla does not create or manufacture the Giga Press. It is built by an Italian/Chinese firm called Idra. There are about 20 of the Idra presses shipped so far, and Tesla has the most of them. It's a killer machine, and weighs so much you have to build a special floor to hold it. The cycle time is incredibly fast.
Everyone knows Musk asked a few companies to make the giga press and only Idra said ok/maybe it's possible. It wouldn't exist if not for Tesla and Idra. Now, like iPhone, everyone else is following.
@@newdrew2744"Idra" just an Italian name for a Chinese manufacturer. You have to ask yourself how much money you want to give China. Tesla has built his company on tooling and products, "dumped" undervalue from China. Laborers in the United States have become the cheap labor that used to be what was outsourced to other countries. With Teslas union busting history, firing anyone that have any interest in starting a union at a Tesla facility. There's a reason thousands of people are willing to put their jobs on the line, not only for themselves but for all workers to earn a fair wage.
@@paul5683every now and then I wonder what problems there are in reading before making statements: IDRA Presse founded in 1946 by Adamo Pasotti in Brescia in 2008 taken over by L.K. Tecnology Holding ltd: this is not a fake Italian company invented by the Chinese, apparently it is a company in which they thought it was worth putting their money.
@@paul5683Your post makes so much sense. (NOT)
Tesla should go with the one that works best for the task at hand, it may be both approaches in use at the same time, not either or.
I’d say $4 mill is cheap for a mold. 150 cars would pay for it. Some people buy a watch for $1\2 mill.
If you get into a fender bender, do you scrap the entire car like the G M Saturn?
I am very confused with this report of a single casting for the bottom. The bottom is literally the structural battery pack, and the front and rear casting are the remainder of the bottom. Making those one piece would greatly complicate the battery assembly. I could see the cast be the front, back, and sides, as the top has no cross structure.
That's what it is and what the design patent shows. I think the bottom casting is a Reuters story to throw people off.
Nothing they say about tesla&tsla can be trusted imo. 👍🏻
Tesla can combine the priciples of the unboxed process with gigacasting 2.0. We did see lately in the video from a trade show how they design sub assemlies in the front and rear to be fitted in one direction only. This makes it easier to use optimus robots and cuts down on assembly time. Nothing would stop them to use this methods if the gigacasting of the skate board would be done in one piece. This is entirely possible with small design changes to the Idra press. Just imagine a machine using platens twice the size of the 9,000 ton press side by side. It would have two toggle mechanisms for closing/clamping and six tie bars. Beside the platen size which would extend the horizontal dimension two fold, the components of the machine would be largely the same.
It's a contradiction.
The whole point of unboxed is to work on 4 sides of a unit then bolt the units together.
Assuming 3 units, that's 12 "workers" total simultaneously.
The single casting is a retrograde set back to 4.
Sand core for rapid prototyping through production approval and metal mold for actual production.
Tesla has perfected the production line so that it’s innovative, efficient and upgradable so that the process is self sustaining. The next big item is Automation of driving, this will change the motor industry. Tesla will achieve the manufacturing to such a point that they are years ahead of the competition. The next big step for the brand is providing an effective, efficient means of generating electric its storage giving the freedom / independence of not needing the grid as a supplier. This market is much bigger than the car, truck industry.
Sand casting for testing only? Metal die casting for mass production units.
3d printed p20 molds from mantel would work if you add conformed cooling and collapsible inserts should do the trick.
I wonder why the never tried reorienting the horizontal giga press vertically. Reduce the ram sets required to one and getting a gravity assist, reducing the ram sizes whilst still getting full clamping pressure.
Well for one, gravity Assist in one direction is gravity Resist in the other, and even on the Assist side you have to control that drop.
@@GT4viper Great point. What I'm thinking about is that the lower half of the die base is fixed, requiring no rams. The upper die rams only require the target clamping force minus the mass of the moveable ram assembly. Something like a drop forge design modified into a die casting forge.
A search of "largest drop forge" returns plans for machines that generate 40,000 tons of clamping force.
"[...With a new concept for the design and construction, Siempelkamp made it possible to bring together practically incompatible customer requirements in a single solution. The design is a four-column under-floor press with external main cylinders and hydraulic parallelism control, to compensate for the diverse vertical expansions associated with the eccentric stresses. It permits the production of high-tech drop-forged parts more safely and reliably, even faster than before, and at lower cost.
The press weighs approximately 5,350 metric tons, due to the heavy-duty design of the press frame, in order to provide the rigidity required. The moving mass of the upper moving cross-head alone weighs 2,550 metric tons, and the upper die can add up to 200 metric tons.
Thanks to the design of the cylinder heads, the four main cylinders are highly durable. The design provides a guarantee for 10 million full-load strokes...]"
"Tesla has been making use of large gigacasting...for model 3 and Y" @ 1:32 That statement is not quite correct, Y is using gigacastings but 3 has not, there is no report that show they are using it for Highland Model 3 yet AFAIK
Yeah I think just the rear of the Model 3 at least was using the Giga casting:
www.tesmanian.com/blogs/tesmanian-blog/tesla-to-produce-model-3-with-rear-single-piece-casts-using-parts-from-gasoline-cars
Though this article here appears to say it's both. Article might be wrong though.
www.designnews.com/automotive-engineering/teslas-switch-giga-press-die-castings-model-3-eliminates-370-parts
Why not use that sand method for creating the steel molds that are made from the CNC method? Instead of taking months to grid down a single block of steel for the desired part it could be cast and fine tuned.
Great for manufacturing efficiency…service techs, body shops and mechanics are going to hate it though lol
Tbh, the limiting factor for the 25k car is fsd, they can change the design dramatically once the car drives better than human
I love the developing process we are witnessing. It's as a police chase through an engineer's wonderland. Go for it guys.
So what happens when you have an accident and smash the front end of your Tesla? It's all one piece. Can't just replace a fender. Insurance companies will just love the costs of repairs.
@@seanstehura7179 lol you get a new car
Giga Casting is the future. It's simpler and the hurdles of engineering will be overcome.
I'd go with both casting methods. Separate the factories and models and teams into the two methods, then have them compete. Over time one method will likely show a clear advantage, and in the mean time developing both methods will result in a lot of new knowledge.
At lab scale, yes. But at factory scale, too expensive. You will have 50% loss cost at the end. Inside one team you can do A/B development, but cross-checking frequently on smaller outcomes moving the whole process forward more efficiently.
You can't do both. The cost at putting one of these online is in the millions. Besides, that 4-way casting machine is an impossibility..... running one is hard enough, and now you need 4 to run at millisecond precision with all 4 having perfect shot profiles? Not a chance.
Interesting topic.I am assuming that 12KT Giga Press will be bigger heavier than 6KT press but it many not not be double the cost. It will be cheaper to produce one piece sub-frame in one machine instead of two pieces in two machines. Let that sink in!
"Tesla is playing with laptop batteries". Bahaha.
the new single casting could be a casting for the upper car structure which would be added after the 3 unboxed pieces have came together. It could cast both the right & left door frame & roof structure as 1 piece instead of the current sheet metal pressed pieces.
CT is *not* much exoskeleton design, more unibody. If it were it wouldn't need all the internal structure such as big castings that it has.
tESLA does not make the gigapress. It is made in italy Italy
The Giga Press program is a series of aluminium die casting machines manufactured for Tesla, initially by Idra Group in Italy. Idra presses were the largest high-pressure die casting machines in production as of 2020, with a clamping force of 55,000 to 61,000 kilonewtons (5,600 to 6,200 tf). They do not make them please make the correction.
Thank you This site is moronic
I never miss your program. The news is current and very well presented.
Where is the Gigapress 2.0 Grünheide? Shanghai? It working now?
Ok, that’s it. I’m supporting this channel. This subject is above my pay grade and outside my AOE, so all I can do is marvel at the pace of innovation. Not to mention your research, info and presentation prowess, and for having a financial background, your understanding of physics and engineering concepts are incredible. Thx for all the hard work.
The Unbox method will require precise timing driven by software. Software is where Tesla excels. Once perfected this method will put the competition at a huge disadvantage as production cost will go way down with the Unbox process.
One part is better then two parts.
Elons decision in giving users access to FSD was a great move, not only will it be bought by people but also the amount of data being collected by road users would of had a great impact. More data more the AI learns to drive
And? Give it now a Gigapress 2 Production? Fremont? Shanghai? For the M3H?
I hope this idea is better than the structural battery pack
I wonder how they go about and how often they have to grease these presses? Looks like so many parts and the heat has got to bake it out of them
Die casting is a maintenance heavy manufacturing process. You are right, the special grease they use is high molybdenum goo. The actual steel tool needs to be torn down, cleaned, repaired and reassembled on a fairly regular basis. If not, preventive maintenance like that soon turns to major repairs. Things like an ejector pin getting bent. When they get bent, the bent pin starts to screw up the precision hole that it runs in, then the casting starts flashing really bad around the hole, then the flashing will push down into the hole, further screwing up the hole. It all goes to he'll in a big hurry and some robot isn't going to be able to keep it from happening. This brings the fact that they will need multiple molds of the same product because production can't rely on one tool. Like the guy in the video said, these are multi million dollar molds. The trouble is that these are along with most of the Tesla tooling, "dumped " Chinese products. Yes, "dumped " Chinese products, they have been doing that shit for decades and Tesla is benefiting from that "dumped "resource.
It's a good thing that the FAA isn't involved here or Tesla would be hammering out the parts by hand.
Hahaha!
$4 million for single gigacast die.. It takes some tooling time :)
As always excellent analysts
The best path forward is likely a few pieces. It is to be commended that Elon is exploring casting techniques and alloys. There should be great benefits to properly developed techniques. It was not so many years ago Semi- solid casting techniques were developed. I don’t agree with your assertion that sand casting is useful for rapid development since the grain structure is completely different.
I wonder what the throughput difference in ‘slow injection’ vs ‘fast injection’ casting really are? Fast injection is required to avoid imperfections, voids, in the casting. Chasing alloys and mold design helps here; it could be that this is why the rapid and low-cost prototyping of the sand casting is being explored-for casting quality-lowering fault rates (very) expensive parts loss.
Great stuff, thx
It’s the same methods as ship builders use: modular components assembled at a: “marrying” location. Minimizing sub assemblies, by having larger main components joined together at a final location. Ship builders have been doing this for several years. Nothing new here.
Wow, dude, you're so smart you should go work for Tesla!
The question I don’t hear anyone asking is what happens to a cast car frame in a crash, and what the repair process would look like. Stamped/welded frames tend to bend rather than crack, and can be straightened again. Will cast frames do the same, or will the castings be more likely to crack instead of bend. If that happens, how do you repair them? Can you use welding to repair cracked castings without compromising strength?
I have no idea of the answers to these questions, but I don’t understand why no one is asking or talking about them. (Maybe my gut is wrong and it’s just a complete non-issue?)
Depends where it went bend/damage, but yes, once they crunch enough they're done unlike other cars that you might be able to tapper out again. Problem is - this saves so much time and money in the purchase side - that - this wont change from a mfg. side of things. Its no different than when you phone breaks. Live in a throw away world - but "cost" is the main driving force into why we do.
Your question has been answered previously. "Electrified". (Dillon Loomis) had a segment on it. Short answer is castings are easily repairable.
@@almostthere100 Thanks for that note, I'll check out the channel/vid!
Watch Sandy Munro on this. I’d rather be in a car crash with a casting than without.
@@FutureSystem738 Thanks for that note, I'll check it out. Sandy's a knowledge-monster in the car biz :)
So what happens after a car accident and repairs need to be made? Do they have to replace the whole “Giga panel?” Sounds like any repair would be quite expensive, and it would be easier to consider it a total loss.
The panels are the same stamped metal, it's the underbody that is cast.
My guess is that Tesla knows all of this and is going to shock us anyway!
Good point.
So 3000euro tesla model 3 confirmed?
Two gigapresses operating at the same time vs one big one? It seems to be a diminishing return. Removing one part doesn't seem advantageous, especially if it reduces efficiency by forcing linear manufacturing.
Having said that, Elon is the man who is most qualified to know the best way to go.
Yes that's a good point. Something else to consider is the extra time and machinery needed for then welding those pieces together.
@@TMIOTesla Another is the fact you can work with two pieces though - if there is an issue with one side - you have to recast vs just garbing another part. Aka, you do loose the ability to repair as well to some level as now you have to fix the whole thing - vs just a section.
How would the casting of the entire underbody jibe with the unboxed process? I think this news is bogus.
Great! So with a giant casting, you get into a collision, and the car is irreparable scrap!
Castings can be cut an rewelded
I guess the service & repair cost will go higher since they will need to change the whole cast piece than the small part that is damaged...congratulation EV´s fans.
All casting machines are subject to wear. Interesting to know how many pieces can be cast before they go out of spec.
I mean I get that more you can press the less over all parts you have to put togather, but isnt there a point that it doesnt matter? I mean sure you get to skip a step, but the time to do that step vs the time you have to press the whole thing I would think wouldnt make that much of a differenc I wouldnt think.
It's a good point. I was thinking about that too. It looks liek Tesla still needs to design what works best, given the Unboxes Process. But if they go with Giant casting press, that could save cost and floor space and even speed, versus say 2 large casting machines and a series of robots that need to weld the parts together.
5:20 the unboxed process is all about giving tesla bots access to the vehicle, right?
First off the plastic modeling companies have been doing this for almost 100 years (yes I realize not apples to oranges). Secondly it's not a Tesla press. The press is the genius creation and engineering wonder of IDRA Group an Italian company.
Many new ideas.
Spontaneous combustion.
Manufacturing cost savings will be huge. The problem I see if this vehicle gets into an accident, the higher probability of the vehicle being totaled because of the damage done to an exoskeleton. This could result in higher insurance premiums. Higher cost of ownership.
I don't think it's a true exoskeleton. However we might need to wait for a tear down to know for sure.
Great news.
This Giga technology provides an advantage for the vehicle assembly process by casting larger components. The shortfall is the exorbitant cost of the tooling and multiple revisions. Even if this cost can be reduced, maintenance becomes a nightmare. Small damage to the part via accident will require a major "component replacement." This cost is hidden from the consumer in terms of premium insurance. Now, we know why Tesla's car insurance is at least twice the regular rate for traditional cars. The Chinese won't probably adopt this option.
The giga press idea was amazing truly revolutionary the pick up truck they make is garbage. It’s going to go nowhere fast, but this technology may help reduce the cost of their other vehicles. Of course it comes with its own issues because now insurance rates for these vehicles go up because a tiny bump to the rear totals out the whole vehicle. That’s not a problem for the manufacturer necessarily, but customers might not like the higher insurance rate.
Elon is nuts! 😢
This is 48 Volt DC and Either Net Buss for communication, Elon is out of the world.
Cybertruck is not an exoskeleton btw, as confirmed by Sandy Munroe.
Nothing new under the sun, that's "Hot Wheels or Tunka trucks" toys are made.
Lovely
Parallels, NOT Parallelizes (not an actual word)
Let me get this straight: Tesla/Musk owned Space X regularly wasted entire collections of multi million dollar boosters in development and you think they’re worried or would be concerned about a $1.5 million press.😂😂😂
ออกแบบ ระบบ บริหาร เหมือน ios เลย
คือ พัฒนาทุกส่วน (ทำได้ยังไงนะ)
(จริงๆ คนทั่วไป ทำ 1.0 ได้ก็หยุดแล้ว)
- cost non-value
- new-cost value added กล้อง มีแล้วยินดี
อย่างที่เราทราบกัน Tesla คือผู้บุกเบิกในการใช้แท่นพิมพ์หล่อขึ้นรูปขนาดใหญ่อย่าง Giga Press ขนาด 6,000 ถึง 9,000 ตัน เพื่อขึ้นรูปโครงสร้างด้านหน้าและด้านหลังของโมเดล 3 และ Y กระบวนการ Giga Casting ทำให้ลดต้นทุนการผลิตของ Tesla ลดลงอย่างมา และทำให้คู่แข่งต้องดิ้นรนเพื่อตามให้ทัน
.
ล่าสุด Tesla ได้คิดค้นนวัตกรรมที่จะทำให้สามารถหล่อส่วนล่างที่ซับซ้อนของรถยนต์ไฟฟ้าได้ในชิ้นเดียว จากประมาณ 400 ชิ้นส่วน เทียบกับรถยนต์ทั่วไป เทคโนโลยีนี้จะเข้ามามีส่วนช่วยลดต้นทุนการผลิตรถยนต์ของ Tesla
(ลดต้นทุน ครึ่งนึง คือ จัดกระบวนการไหนออกได้บ้าง)(ชิ้นส่วนเยอะการหล่อขึ้นรูปทีเดียวเลยคุ้ม)
.
โดยเป้าหมายที่ Elon Musk ใฝ่ฝันไว้คือสามารถทำให้ต้นทุนของการผลิตลงครึ่งหนึ่งหรือ 50%
.
ความรู้ความชำนาญในเทคโนโลยีการหล่อขึ้นรูปนั้นจะเป็นแกนหลักของกลยุทธ์การผลิตของโรงงาน Tesla ซึ่งเป็นกุญแจสำคัญในการผลิตรถยนต์ไฟฟ้าราคาถูกกว่าหลายสิบล้านคันในอีกสิบปีข้างหน้า
ประเด็นคือ ออกแบบบระบบ แบบนี้ ใช้ทุน สูงมาก แผนความสามารถในการคืน ทุนต้องชัดมากๆ ระยะ 1-2-3 ที่จะขอทุนเพิ่ม เพื่อไประดับต่อไป
- ระยะ แรก ผ่านไปแล้ว คือทำให้ tesla sexy และขายได้ ที่เหลือคือ การลดต้นทุน เพื่อไปสู่เป้าสุดท้าย
- พอรู้แล้วแหละจะมาทางนี้ ที่เหลือคือ จะหาใครมาทำ
คนที่เก่งพอ ที่จะทำได้ พร้อมทุน ที่จะใช้หนุน จนสำเร็จ
- ถ้าสำเร็จมันคุ้มแน่นอน เพราะ need tesla มันสร้างมาจนเยอะอยู่แล้ว
อีกอย่างคือต้นทุน
Pretty
HAHAHA ! these 9T or 16 T press which can never be made in the US.
No, I don't think there are any factories in the US for making giant casting machines.
not 16 000 T ? :)
This gonna end up like SWATCH watch, an other beautiful unrepairable product that pile ups in trash fields
So in theory it would be nigh on impossible to repair for car repair garages or thise who make a living fixing wrecked cars
Car manufacturers should stand their ground and offer consumers cheap, simple, easy-to-repair, basic cars.
If consumers had the opportunity to buy such ready-made Tesla Gigapress car bodies with a variety of low-power internal combustion engines, for example. Koenigsegg Quark Motor,- without any fault-prone HI-tec technology, I believe that the trade would go at a completely different pace.
Elon wont go for the middle ground
We should not accept mass production of goods such as the Structural battery, its does not allow for cost effective recycling. It’s either good or bad unlike previous modular batteries which could be repurposed as power storage, be it less capacity but lives onto to an extended life. And with all this cost saving, I’ve yet to see the price of Tesla come down. Tesla also seems to escape the consumer demand for a new model or refresh each year.
Great Only problem is the worlds' Electrical grids are Barely able to meet existing Demands.
Imagine what adding on a Million (or More ) EVs charging needs ... will cause
They are not castings, they are pressings. Where was the 16,000 ton press? 9k ain't 16k. Click bait shit.
Thought the exoskeleton idea got scrapped?
It did. All the pics of the truck show standard design underneath.
@@rtz549 Thanks. The voice kept saying exoskeleton which is confusing
If you break something on your new car you'll need a new car, rather than a new part.
Nonsense.
Sounds like Omar
Tesla always reminds me to Coca Cola. Big image but cheap contant. And now they even have a can. 🤣