2024 Solutions Webinar Series

Giga casting technology trend

Grant Xu
New manufactory revolution in Automotive world Sales Director,
Bollhoff (China) Fastenings Co., Ltd.
1st of March 2024

Copyright© 2024 by S&P Global Inc. All rights reserved. Solutions Webinar Series.
Agenda
• Brief introduction about Böllhoff company
博尔豪夫公司介绍
• Tesla bring the new manufactory revolution
特斯拉如何带来这项技术革命

• Introduction about giga casting technology

一体压铸技术和产业链介绍
• Which OEM use the giga casting technology
哪些整车厂已经开始使用一体压铸技术

• Summary
总结

Copyright© 2024 by S&P Global Inc. All rights reserved. Solutions Webinar Series. 2
Agenda
• Brief introduction about Böllhoff company

• Tesla bring the new manufactory revolution

• Introduction about giga casting technology

• Which OEM use the giga casting technology

• Summary

Copyright© 2024 by S&P Global Inc. All rights reserved. Solutions Webinar Series. 3
Böllhoff History
From a hardware dealer...

Start of in-house Expansion into

First branch in Bielefeld production in Bielefeld foreign markets
总部设在德国比勒菲尔德 内部生产，为大众配套 国际化拓展脚步
Foundation as wholesale
ironmongery business in
Herdecke 五金零售商
Today and in the future
147年，传承四代，始终坚持
生产紧固件，提供紧固技术
解决方案。是德国排名第一的
紧固件生产商。
Bollhoff (China) Fastenings Co., Ltd., Subsidiary of the Böllhoff Group

CHINA - The 6th Manufacturing Plant of the Böllhoff Group

Manufacturing processes on site

Injection moulding 注塑
Cold forming 冷镦
Turning 车削
Coiling 绕簧

2004 310 701

Established Employees Sales 2023 (million
RMB)
Bollhoff (China) Fastenings Co., Ltd., Subsidiary of the Böllhoff Group

• Opening date of Phase I

2005

• Opening date of Phase II

2008

• Opening date of Phase III

2014

• Opening date of Phase IV

2019

• Opening date of Phase V

2023

总共有5期厂房。1,2,3期20亩地，
4期22亩地，5期25亩地。
Our products:

Products manufactured in Wuxi plant （轻量化紧固件）

RIVKLE® RIVKLE® Stud AMTEC®

Blind rivet nuts Blind rivet stud Thread inserts

KOBSERT® HELICOIL® FLEXITOL®

Thread inserts Wire thread inserts Tolerance compensation

SNAPLOC® TEPRO® TEPRO® K’ in K’

Plug-in connections Engineering plastic products Screwing solutions
and subassemblies
Agenda
• Brief introduction about Böllhoff company

• Tesla bring the new manufactory revolution

• Introduction about giga casting technology

• Which OEM use the giga casting technology

• Summary

Copyright© 2024 by S&P Global Inc. All rights reserved. Solutions Webinar Series. 9
100 years Automotive Manufactory revolution
1885 to 1913, manual working
01 with low efficiency and high
cost.手工作业

From1913, Ford started to

use industry production line:
reduce cost, increase 02
efficiency.流水线作业

03 1950s, Toyota lean production; reduce

waste, increase efficiency. 精益生产
1980s, VW start to use
platform and module
04 production, it reduce the
development time and cost, 2020s, Tesla start to use
increase the standardization. giga casting body, to
平台化，模块化，标准化 05 reduce parts and cost,
bring the production
revolution. 一体化压铸

◼ In the past 100 years automotive industrial history, every 30 to 40 years, there will be a
manufactory revolution. Every time, the first one who make the revolution will take big
advantage in the competition on the market. 汽车工业过去百年，每隔三四十年会诞生一次新
的技术革命。谁引领潮流，谁就占据市场领先。
Copyright© 2024 by S&P Global Inc. All rights reserved. Solutions Webinar Series.
10
TESLA Giga-casting idea

◼ Elon Musk’s the first principles thinking and Tesla’s hiring the top materials science expert Charles
Kuehmann from Apple in December 2015 are the two most important forces driving the industrialization of
giga casting technology. 马斯克的第一性思考原理和从苹果公司挖来的材料学科学家查尔斯是特斯拉一体化压铸工
业化成型的关键两项驱动力。

◼ Tesla CEO Elon Musk said: “With our giant casting machines, we are literally trying to make full-size cars in
the same way that toy cars are made” 为什么不能像制造玩具车一样，使用巨型压铸机去生产一辆整车呢？那将会
是多么简单啊，没有人做过，不代表不能去做。

Tesla’s concept of a giant unibody casting machine. 18th of Jan 2021, from Elon’s twitter.

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TESLA Giga-casting underbody + Front body

◼ Giga-casting will help car manufactory to have less space, reduce the stamping parts, reduce the welding,
gluing and riveting process. It will increase the production efficiency and reduce the cost. 特斯拉使用一体压
铸技术的目的是要减少场地，节约零件数量，减少连接工序种类，做到降本增效。

◼ Model Y rear underbody first to use the new production method, it helps reduce the components from 70 pcs
to 2 pcs. Tesla Cybertruck’s front and rear body is also using the same way to produce. MODEL Y 地板第一个
使用一体化压铸技术，随后在皮卡Cybertruck上前舱后地板都使用了这项技术。最终证明这项技术是可行的。

There are 2 die-casting machine (6000t) in Tesla Fremont factory, 3 in Austin factory, 5 in Shanghai factory, 8 in Berlin
factory

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TESLA Giga-casting underbody + Front body
◼ From Tesla’s patent file, the cycle time is about 120s per body part; right now they can reach 147s. So, one
machine will produce: 24h*60m*60s/147s *0.75 (OEE) = 441 pcs underbody parts per day. 按照特斯拉一体压铸
工时147秒计算，一台压铸机一天大约可以生产400多个工件。

◼ Tesla said: 40% cost saving on rear underbody, 79 pcs parts per car reduced, 35% floor space less. 按照特斯
拉自己总结，在MODEL Y后地板应用上，会带来40%的降本，79个部件被减少，35%的生产场地被节约。

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Agenda
• Brief introduction about Böllhoff company

• Tesla bring the new manufactory revolution

• Introduction about giga casting technology

• Which OEM use the giga casting technology

• Summary

Copyright© 2024 by S&P Global Inc. All rights reserved. Solutions Webinar Series. 14
Giga-casting technology

◼ Traditional 4 kinds of Automotive manufactory process: Press, Welding, Painting, Assembly. 传统的汽车生产
四大工艺：冲压，焊装，涂装，总装

◼ Giga casting process is using giga casting machine to integrating press and welding process, to use the die
casting manufactory way to produce the whole-body part, instead of pressing hundreds of parts then
welding them. 一体化压铸技术主要替代的是白车身的冲压和焊装环节

Press shop Body Welding shop Painting shop Assembly shop

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Giga-casting technology

◼ Giga casting process is using high pressure giga casting machine to integrating press and welding process,
to injects molten aluminum into casting molds to produce the big car body parts, instead of pressing
hundreds of parts then welding them. 一体化压铸指的是车身件的一体化，即原本设计中多个单独、分散的小件经
过重新设计高度集成后，再利用大型压铸机进行一次成型，省略冲压和铆焊的过程，直接得到一个完整大车身零件。

◼ Italy’s IDRA, Switzerland’s Bühler, China’s LK Group, YIZUMI, Haitian are providing the house-size giga
casting machine with clamping force from 6000 ton to more than 9000 ton. 目前，意大利意德拉，瑞士布勒，中
国力劲，伊之密，海天等厂家提供一体压铸需要的巨型压铸机和压铸岛，一般锁模力6000吨以上被称为巨型压铸。

High speed High pressure From liquid to solid One stop process

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Giga-casting technology
◼ Giga casting’s up stream industry is including Aluminum raw material, giga casting machine, mold; mid stream industry
is including die casting supplier and some OEM; down stream industry is including OEMs. 一体压铸的上下游产业链如下

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Giga-casting technology bring 3 kinds of cost saving

◼ First, reduce the production line building cost. In the past, you need press machine, welding line, test
machine, transportation, huge investment; now you only need 3 to 5 giga casting machine cells. Saving a lot
of investment and space. 第一层降本：减少大量的生产线投资成本（冲压和焊装），并节约了场地

◼ Second, reduce the raw material cost. The giga casting used raw material can reach 95% of recycle use; and
reduce the BIW weight by 10 to 15%. 第二层降本：节约原材料成本 （不良件95%可以回收）并减重10%-15%

◼ Third, reduce the labor cost. Using giga casting technology will reduce the welding line operators, from 200,
300 people to about 30 people. 第三层降本：大规模减少现场人员数量

Tesla Model 3, with 370 pcs body Tesla Model Y with rear giga casting Tesla Model Y with front and rear
part, and 5000 joints. body, reduce 74 pcs body part, and giga casting parts, reduce 1600
reduce 700 joints; underbody joints; BIW weigh reduce by 10%.
manufactory cost reduce by 40%.

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Giga-casting technology bring 3 kinds of efficient increase
◼ First, reduce press and welding time. Traditional OEM need own manufactory hundreds of body parts with many different
processes (will use about 130 robots); but with giga casting process, the workload and complexity will reduce a lot. (One
giga casting machine replace 130 robots) 第一重效率提升来自于一体压铸生产比传统冲压焊接流水线作业节约很多工时

◼ Second, reduce the joint time. Welding, riveting, gluing process are reduced, it will save lot of time. 第二重效率提升来自减少
连接工艺的时间（减少了铆接，焊接，粘接等工艺）

◼ Third, reduce the project timing. In the past, OEM need 3 round of mapping process (6 month) to make sure different body
parts can be joint properly, but with giga casting process, OEM will only 2 month, 1 or 2 round mapping process. 第三重效率
提升来自项目周期的缩短，整车匹配原本需要3个轮次6个月时间，可以缩短到2个月，1到2个轮次。

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Giga-casting technology bring 3 kinds of problem
◼ First, poor maintenance economy. 带来维修经济性的问题，以及保费的增加。

◼ Second, the giga casting mold cost is very expensive, lifetime is about 150,000 times, can only produce one part. If OEM’s
car is not selling very good, then it means huge losses. It might fit for Tesla but might not fit for many NEV companies. For
traditional OEM who has existing press shop and welding line, it will be also a huge loss if they decide to choose giga
casting way to manufactory the car. 一体压铸岛和模具的投资比较大，而且只能生产一种产品。适合少品种大批量新主机厂。

◼ Third, the giga casting mold is very heavy (100 ton), changing the mold will take very long time, at least half a day. Not
possible to quick change the mold and produce the body part for different car models. If one OEM have only one or two
car model, it is very good to choose the giga casting process, but if one OEM have more than 10 car models, it is not
possible to choose this way to produce the car. 模具非常重，换模时间长，无法柔性生产不同车身零件。

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Agenda
• Brief introduction about Böllhoff company

• Tesla bring the new manufactory revolution

• Introduction about giga casting technology

• Which OEM use the giga casting technology

• Summary

Copyright© 2024 by S&P Global Inc. All rights reserved. Solutions Webinar Series. 21
OEMs use Giga-casting technology
Integrated
OEM & Model GIGA PRESS Supplier GIGA CASTING Supplier Clamping Force (Ton)
Parts
IDRA & LK
TESLA Model Y Tesla Rear 6,100
Machinery(China)
Tesla
Tesla MY RWD Berlin IDRA Front & Rear 6,100

Tesla Front & Rear

TESLA Cybertruck IDRA 9,000

Front & Rear

Xpeng G6 LK Machinery Xpeng 7,000

Xpeng X9 LK Machinery Guangdong Hong Tu Front & Rear 12,000

Zeekr 009 Rear

LK Machinery Zeekr 7,200
Volvo M90
Rear
NIO ET5-ES6 LK Machinery Wencan 6,000

Rear
NIO ES8 Haitian Millison 8,800

Front & Rear

Huawei AITO M9 LK Machinery Wencan 9,000

Rear
Xiaomi SU7 Haitian Xiaomi 9,100

Copyright© 2024 by S&P Global Inc. All rights reserved. Solutions Webinar Series. 22
OEMs use Giga-casting technology

◼ Tesla was the first to widely use the giga casting technology. 特斯拉是第一个广泛使用一体压铸的主机厂。

◼ On Chinese EV market, more and more NEV companies are starting to use it. 越来越多中国新能源车企开始追随特斯拉脚步。
（蔚来，小鹏，理想，问届，吉利，小米…）
◼ On oversea market, General Motors is reportedly using it for its upcoming flagship EV, the Cadillac Celestiq. Volvo, VW,
Toyota and Hyundai have similar plan as well. 海外车企，如凯迪拉克，沃尔沃，大众，丰田，现代等纷纷开始试水一体压铸。

◼ More and more OEMs are following Tesla and starting to use giga casting technology. It is a blue sea market. 我们判断会有越
来越多的主机厂在特斯拉的引领下投资并使用一体压铸技术；目前上下游产业链是巨大的蓝海市场。

Two 9,000-ton Tesla Cybertruck Giga Casting Two 9,200-ton hyper Casting machines at Beijing
machines spotted at Giga Texas in drone footage. Xiaomi Factory.

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Agenda
• Brief introduction about Böllhoff company

• Tesla bring the new manufactory revolution

• Introduction about giga casting technology

• Which OEM use the giga casting technology

• Summary

Copyright© 2024 by S&P Global Inc. All rights reserved. Solutions Webinar Series. 24
Summary

◼ Tesla bring the giga casting technology to Automotive manufactory process, it is a revelation. 特斯拉在汽车行业引领了一体压
铸风潮，带来了技术革命。

◼ Giga casting bring OEMs many benefit but also some problems. Not all the OEM’s project is suit for this manufactory
process. 一体化压铸给主机厂们带来很多好处，但是也会产生一些问题。当下，不是所有的主机厂都适合使用这项技术。

◼ More and more OEMs are following Tesla and starting to use giga casting technology. Some of them do it in house, some of
them work with tier supplier. It is a blue sea with good business opportunities for many suppliers. 越来越多的主机厂将会在特
斯拉引领下使用一体化压铸技术。有些主机厂自己生产，有些是委外生产。这是一片蓝海市场，对产业链上下游供应商是一次巨大的商
机。

◼ Rough calculation about giga casting market size for year 2024 and 2025 初步估算一下市场容量:
2024: 10 million NEV cars * 0.5 (pure EV car) * 10% (use giga casting) * 2000 RMB= 1 billion RMB
2025: 12 million NEV cars * 0.5 (pure EV car) * 20% (use giga casting) * 4000 RMB= 4.8 billion RMB
On year 2027 and 2028, the number can be more than 10 billion RMB. 这将是一个快速增长的百亿级别的市场！值得大家的关注！

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