Hyundai is taking a page from Tesla as it plans to model a new EV production method after its Giga Casting. The new process,”hypercasting,” can significantly cut costs while boosting output.
According to an exclusive report from the Korean newspaper Hankyung, Hyundai’s new EV production method is inspired by Tesla’s Giga Casting.
The process involves injecting molten aluminum alloy into casting molds that harden into the vehicle’s frame. Since introducing the method in 2020 at Tesla’s Fremont Factory, the EV maker has introduced it at its plants in China and Germany.
The massive machines produce parts much bigger than what the auto industry was used to. Automakers can save much-needed time and resources without the need to bond multiple parts (it can also help reduce the vehicle’s weight). Tesla is said to have reduced costs by about 30% using Giga Casting.
Traditional methods include drilling thousands of holes in around 70 steel plates and welding them together individually. You can see how it saves time and money.
Tesla production at Gigafactory Texas (Source: Tesla)
Hyundai takes a page from Tesla to boost EV production
Hyundai, which reached a tentative wage pact with its South Korean labor union Tuesday, agreed to a “special agreement for future growth.” The goal is to boost domestic investment to convert existing ICE manufacturing plants into “core manufacturing bases for future vehicles.”
Korea’s largest automaker has decided to develop its own casting, processing, and assembly plant, with production planned for 2026.
The company already filed for the “hypercasting” trademark with the United States Patent and Trademark Office on August 21, 2023.
Hyundai begins 2024 Kona Electric production (Source: Hyundai)
Hyundai isn’t the only one looking to take a page from Tesla to boost EV production. Several automakers, including Toyota, Volkswagen, and Volvo, are looking to introduce similar processes. China’s Geely has already introduced the method to build ZEEKR models.
The South Korean automaker is also looking to counter Tesla’s proliferating Supercharger network in its domestic market with its own ultra-fast chargers.
Hyundai has had success so far in transitioning into the electric era with EV models, including the IONIQ 5, IONIQ 6, and Kona Electric. However, to keep up with EV leaders like Tesla and BYD, Hyundai sees an opportunity to transform its production network.
Electrek’s Take
With Hyundai planning to convert its existing ICE vehicle manufacturing network for the electric era, why not upgrade them to optimize efficiency?
Tesla has proven the process not only works but works much more efficiently than traditional methods.
With several other automakers hopping on board, Hyundai looks to advance its position in the industry with plans to become a top three global EV producer by 2030. By then, the company expects to have 31 EVs under the Hyundai, Kia, and Genesis brands.
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More than $14 billion in US renewable and EV investments and 10,000 new jobs have been scrapped or put on hold since January, according to a new analysis from E2 and the Clean Economy Tracker. The reason: growing fears that the Republican-majority Congress will pull the plug on federal clean energy tax credits.
In April alone, companies backed out of $4.5 billion in battery, EV, and wind projects right before the House passed a sweeping tax and spending bill that would gut the federal tax incentives fueling the clean energy boom. E2 also found another $1.5 billion in previously unreported project cancellations from earlier in the year.
Now, with the Senate preparing to take up the so-called “One Big Beautiful Bill Act,” E2 says over 10,000 clean energy jobs have already vanished.
“If the tax plan passed by the House last week becomes law, expect to see construction and investments stopping in states across the country as more projects and jobs are cancelled,” said Michael Timberlake, E2’s communications director. “Businesses are now counting on Congress to come to its senses and stop this costly attack on an industry that is essential to meeting America’s growing energy demand and that’s driving unprecedented economic growth in every part of the country.”
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Ironically, it’s Republican-led congressional districts – the biggest beneficiaries of the Biden administration’s clean energy tax credits passed in 2022 – that are feeling the most pain. So far, more than $12 billion in investments and over 13,000 jobs have been canceled in GOP districts.
Through April, 61% of all clean energy projects, 72% of jobs, and 82% of investments have been in Republican districts.
Despite the rising number of cancellations, some companies are still forging ahead. In April, businesses announced nearly $500 million in new clean energy investments across six states. That includes a $400 million expansion by Corning in Michigan to make solar wafers, which is expected to create at least 400 jobs, and a $9.3 million investment from a Canadian solar equipment company in North Carolina.
If completed, the seven projects announced last month could create nearly 3,000 permanent jobs.
To date, E2 has tracked 390 major clean energy projects across 42 states and Puerto Rico since the Inflation Reduction Act passed in August 2022. In total, companies plan to invest $132 billion and hire 123,000 permanent workers.
But the report warns that momentum could grind to a halt if the House tax plan becomes law. Since the clean energy tax credits were signed into law, 45 announced projects have been canceled, downsized, or closed entirely, wiping out nearly 20,000 jobs and $16.7 billion in investments.
What’s more, Trump’s Department of Energy announced today that it was killing more than $3.7 billion in funding for carbon capture and sequestration (CCS) and decarbonization initiatives. Eighteen out of 24 projects were awarded through DOE’s Industrial Demonstrations Program (IDP), which was made law in the Inflation Reduction Act. It aimed to strengthen the economic competitiveness of US manufacturers in global markets demanding lower carbon emissions, while supporting US manufacturing jobs and communities.
Executive Director Jason Walsh of the BlueGreen Alliance said in a statement in response to today’s DOE announcement:
The awarded projects that DOE is seeking to kill are concentrated in rural areas and red states. American manufacturers are hungry to partner with the federal government to bolster US industry. The IDP saw $60 billion worth of applications during the program selection process, a ten-times oversubscription.
President Trump claims to be a champion of American manufacturing, but today’s announcement is further evidence that he and his Secretary of Energy are liars.
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A Tesla prototype was spotted at the Fremont factory in California, sparking speculation that it’s the new “cheaper Tesla”, but it looks like a regular Model Y.
A drone operator flew over the Fremont factory this week and spotted a Tesla prototype with light camouflage on the front and back ends.
The vehicle is making a lot of people talk on social media and the media as many think it could be a new “affordable model” coming to Tesla.
Other than the camouflage, the vehicle looks just like a regular Model Y:
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It’s likely one of two things: a new “stripped-down Model Y” or a Model Y Performance.
Model Y Performance is the only version that Tesla hasn’t launched since the design changeover earlier this year.
The “stripped-down Model Y” is what will replace Tesla’s upcoming “affordable models.”
We have been reporting on this new vehicle program from Tesla for a while now.
It came to life just over a year ago as a pivot for Tesla after CEO Elon Musk canceled two cheaper vehicles that Tesla was working on, commonly referred as “the $25,000 Tesla”. Those vehicles were codenamed NV91 and NV92, and they were based on the new vehicle platform that Tesla is now reserving for the Cybercab.
Instead, Musk saw that Tesla’s Model 3 and Model Y production lines were starting to be underutilized as Tesla faced demand issues. Therefore, Tesla canceled the vehicles program based on the new platform and decided to build new vehicles on Model 3/Y platform using the same production lines.
We previously reported that these electric vehicles will likely look very similar to Model 3 and Model Y.
In recent months, several other media reports reinforced that, and Tesla all but confirmed it during its latest earnings call.
Considering this looks like a regular Model Y, it could be the new cheaper and less feature rich Model Y:
Some people are claiming that this vehicle looks smaller than the Model Y, but it’s difficult to tell as the black camouflage on the ends can confuse the eye.
It looks like a very similar size when it passes near other Tesla vehicles:
What do you think it is? Let us know in the comment section below.
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San Francisco-based founder Ahmed Shubber wants to emulate Elon Musk’s success in the electric construction equipment world – and he hopes his new, 32-ton electric bulldozer is enough to make the world sit up and take notice.
Since launching his company, Lumina, in 2021, Shubber has raised more than $8 million and grown the company’s global (!?) headcount to 26 people. That fruit of that team’s labor is the machine seen here. Dubbed “Moonlander,” the first-of-its-kind prototype occupies the physical footprint of something like a Caterpillar D6, but packs the blade and performance of the larger, more powerful Cat D9.
“A D6 could not push that blade,” David Wright, Lumina’s head of UK operations, told the assembled media at the Moonlander’s launch last week. “We can have that blade full of material, full dozing seven to nine cubic meters of material, for eight to 10 hours.”
“Even if you spend all morning heavy dozing and you’re a bit worried about how much juice you’ve used — well, your operators are going to take a union-mandated lunch break, right?” asks Wright. “Plug it in, and in 30 minutes, you’ve put 50% of power back in again.”
Shubber says Lumina is working to raise from $20-40 million for its Series A round to develop the company’s next electric equipment asset: a 100-ton electric excavator called Blade Runner. And, in a truly Tesla-like fashion, Shubber says he’s on track to hit an ambitious $100 million revenue target sometime in the next 24 months.
We’ll see how that unfolds in 2 year’s time, I guess. In the meantime, check out this Lumina promo video for Moonlander, below, then let us know what you think of Shuber’s take on an electric job site in the comments.
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