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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.

Hyundai-Tesla-EV-production
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-Tesla-EV-production
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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World’s largest EV maker unveils new sodium battery electric motorbikes

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World's largest EV maker unveils new sodium battery electric motorbikes

Yadea, which has claimed the title of the world’s largest electric vehicle maker for seven years running, has just announced a new electric motorbike powered by the company’s innovative HuaYu sodium-ion battery technology.

Yadea has long dominated the electric two-wheeler and three-wheeler market globally, but has generally relied on both lithium-ion and lead acid batteries to power its vehicles in different markets.

The newly unveiled electric scooter uses Yadea’s recently introduced sodium battery technology, offering what the company says is outstanding performance in range, charging speed, and safety. Using the HuaYu Sodium Superfast Charging Ecosystem presented by Yadea, the battery can reach 80% charge in just 15 minutes, providing greater convenience for riders.

Yadea’s sodium battery has successfully passed more than 20 safety tests, many focusing on its resistance to fire and explosions under extreme conditions like punctures and compression.

Yadea’s new sodium battery offers an energy density of 145 Wh/kg and a lifespan of up to 1,500 cycles at room temperature, with the company rating it for a five-year useful lifespan. It also includes a three-year warranty for added assurance.

With excellent low-temperature capabilities, the battery retains over 92% of its discharge capacity at -20°C, making it well-suited for colder climates.

Sodium batteries present major advantages

Most electric vehicles used in the West, especially electric two-wheelers, rely on lithium-ion batteries for their high energy density. But sodium-ion batteries offer many benefits over traditional lithium-ion batteries.

Sodium is an abundant element on the planet and is easily accessible, unlike lithium, which is concentrated in specific regions and often expensive to extract. This abundance can make sodium-ion batteries cheaper to produce, reducing costs for EV manufacturers and potentially making electric vehicles more affordable.

Lithium mining also has environmental challenges, such as water depletion and habitat destruction. Sodium, on the other hand, can be sourced from seawater or common salts, offering a more sustainable and environmentally friendly option.

Sodium-ion batteries are less prone to overheating and thermal runaway compared to lithium-ion batteries. This makes them inherently safer for electric vehicles, reducing the risk of fires and improving consumer confidence in EV technology.

Sodium-ion batteries perform better than lithium-ion in cold climates. Lithium-ion batteries struggle with capacity retention in freezing conditions, but sodium batteries maintain efficiency, making them ideal for EVs in colder regions.

Sodium batteries still have challenges to overcome

While sodium-ion batteries are promising, they currently have a lower energy density than lithium-ion batteries, meaning they store less energy per unit of weight.

For EVs, this translates to shorter driving ranges for the same-sized battery. That’s especially important in electric two-wheelers like motorbikes and electric bicycles, which don’t have much extra space for storing bulky batteries.

However, advancements in cathode materials and battery architecture are quickly closing this gap, which Yadea has demonstrated. These sodium-ion batteries still can’t match the energy density of lithium-ion batteries, but as they continue to improve their energy density, the technology’s other major advantages provide encouraging signs for larger adoption in the industry.

Yadea’s status as a major electric motorbike maker also means that its adoption of sodium-ion battery technology could help lead the entire industry towards this battery chemistry, bringing safety and performance benefits along with it.

Last year I had the unique opportunity to visit one of Yadea’s global manufacturing sites.

To see inside the company’s massive and highly-automated manufacturing processes, check out the video below!

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CES2025 | John Deere autonomous mower promises a perfect cut, every time

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CES2025 | John Deere autonomous mower promises a perfect cut, every time

At CES2025, the impressively built-out John Deere exhibit was all about automation. Autonomous job sites, autonomous farms … but it was this new, battery electric, autonomous lawn mowing robot that stole the show.

The self-driving Deere mower robot was positively dwarfed by the giant farm machinery surrounding it, but it continues to prove that humans will pack bond with anything as more than one burly-looking and grizzled man asked what its name was. (It’s Howard. I’ll fight you.)

For his part, Howard packs a 21.4 kWh battery pack that runs a suite of electric motors that includes a drive motor and three cutting blade motors spread across a 60 inch cutting deck – but it’s not the electric motors that make John Deere’s little robot mower cool, it’s the way it works.

See, instead of using “just” GPS data or “just” repeating a pre-recorded run, Howard can do something in between. The way it was explained to me, you would ride the stand-up mower around the perimeter of the area you wanted to mow, select a pattern, then hop off, fold up the platform, and let it loose. Howard mows just the way you would, leaving you to focus on edging, planting, or (let’s face it) schmoozing with the clients.

It’s exactly the sort of help landscapers are looking for.

But that should come as no surprise, of course. John Deere, perhaps more than most companies, knows its customer. “We’ve been in the turf business for 60 years — it’s a core part of Deere,” says Jahmy Hindman, chief technology officer at John Deere, explaining things beautifully. “The work that’s being done in this industry is incredibly labor intensive … they’re not just doing the mowing work. They’re doing the tree trimming, maintaining flowerbeds and all these other jobs. The mowing is table stakes, though, for them to get the business. It’s the thing they have to do in order to get the higher value work.”

Tim Lewis, lead engineer with the commercial automatous mower, told Lawn & Landscape that the industry in general has a high turnover rate as well, making it difficult to hang to people who know where one job ends and another begins. “There’s a lot of nuances it takes to do these jobs effectively,” he explains, “so “Autonomy can help with that.”

The John Deere autonomous commercial mower (there’s no snazzy alphanumeric, yet) leverages the same camera technology as other Deere autonomous machines, but on a smaller scale (since the machine has a smaller footprint). With two cameras each on the front, left, right, and rear sides of the little guy, he has a 360-degree view of the world and enough AI to lay down a pattern, avoid an obstacle, and shut off if it thinks it’s about to mow down something (read: someone) it shouldn’t.

John Deere will have Howard on display through tomorrow at CES in the LVCC’s West Hall. If you’re in town, be sure to go say hi.

John Deere CES2025

SUOURCE | IMAGES: John Deere; Electrek.

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Tesla sales fall, Honda brings back ASIMO, and a bunch of stuff from CES2025

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Tesla sales fall, Honda brings back ASIMO, and a bunch of stuff from CES2025

Despite big discounts and 0% financing, Tesla sales are down for the first time in a decade … but there’s even bigger robot news with the return of Honda ASIMO, a flying car from China, and a whole lot more from today’s episode of Quick Charge!

CES2025 was all about AI – and not just what AI could do, but what AI could do for you. That’s where ASIMO comes in, helping everyone have a better time in there car and not at all just a modern day version of KITT dreamed up by a bunch of Gen X executives (wink, wink). We also cover some neat stuff from Suzuki, Aptera, Volvo, and more. Enjoy!

Prefer listening to your podcasts? Audio-only versions of Quick Charge are now available on Apple PodcastsSpotifyTuneIn, and our RSS feed for Overcast and other podcast players

New episodes of Quick Charge are recorded, usually, Monday through Thursday (and sometimes Sunday). We’ll be posting bonus audio content from time to time as well, so be sure to follow and subscribe so you don’t miss a minute of Electrek’s high-voltage daily news!

Got news? Let us know!
Drop us a line at tips@electrek.co. You can also rate us on Apple Podcasts and Spotify, or recommend us in Overcast to help more people discover the show.

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