Tesla has achieved a breakthrough in making Hot Wheels-like single-piece car casting a reality, according to a new insider report.
In recent years, Tesla has heavily invested in large casting technology to produce vehicle bodies in just a couple of large parts rather than hundreds.
The automaker now operates several of the world’s largest casting machines, which it often refers to as “Gigapress.”
CEO Elon Musk has often referenced how he has been inspired by Hot Wheels toy cars being made in a single cast piece and hinted that he would like Tesla cars to eventually be made like that.
But now a new report claims that Tesla has achieved “a series of innovations to make a technological breakthrough” to “die cast nearly all the complex underbody of an EV in one piece.”
The report is coming from Reuters based on “five people familiar with the move”:
The five people said a single large frame – combining the front and rear sections with the middle underbody where the battery is housed – could be used in Tesla’s small EV which it aims to launch with a price tag of $25,000 by the middle of the decade.
However, the report claims that Tesla has not yet decided to use the new technology for its next-generation vehicle, but it could make a decision as soon as this month.
Reuters claims that one of the innovations involves using 3D printing and industrial sand to create the molds for casting, which can cut the cost and time it takes to make inevitable modifications to the molds:
To overcome the obstacles, Tesla turned to firms that make test molds out of industrial sand with 3D printers. Using a digital design file, printers known as binder jets deposit a liquid binding agent onto a thin layer of sand and gradually build a mold, layer by layer, that can die cast molten alloys.
The report mentions Tesla using Desktop Metall’s ExOne machine.
Another innovation is through material science. The report states that Tesla faced issues with having an alloy that works both with the 3D-printing process of the mold and the performance and safety requirements for a car, but the company has made progress:
The casting specialists overcame that by formulating special alloys, fine-tuning the molten alloy cooling process, and also coming up with an after-production heat treatment, three of the sources said. And once Tesla is happy with the prototype mold, it can then invest in a final metal one for mass production.
Tesla has a strong material science team that it shares with SpaceX, and it has already designed several new alloys used by the two companies.
Finally, the report also mentions that Tesla hasn’t finalized plans for a new bigger Gigapress needed to build those large single unibodies.
Electrek’s Take
Tesla fans like to criticize Reuters for publishing misleading negative reports about Tesla, and there’s definitely validity to the criticism, as we highlighted in a recent report.
However, in this case, Reuters published a very detailed report that makes sense based on Tesla’s plans.
We know that Tesla has been working on such a technology since before the Model Y came to market, and Elon Musk briefly pushed for more innovation in the electric crossover’s platform before backtracking a bit in favor of bringing it to market faster.
A new report states that Tesla will pause part of new Model Y production at Gigafactory Shanghai for 3 weeks to upgrade the lines.
The shutdown will extend beyond the regular Chinese New Year.
The Chinese New Year is technically 2 weeks long, but the official holiday lasts a week, during which significant parts of the country’s industries shut down.
That includes the auto industry and Tesla, but it looks like the American automaker plans to do things a bit differently this year after having just started production of its updated Model Y at Gigafactory Shanghai.
According to a new report from Bloomberg, Tesla plans to shut down part of its new Model Y production lines from around January 22 to February 14.
In comparison, Tesla only plans to shut down production of the Model 3, the only other vehicle produced at the plant, from January 26 to February 3.
Tesla only recently started production of the updated version of its best-selling electric SUV. The report states that the automaker will take advantage of this extended Lunar New Year shutdown to upgrade parts of the production lines in order to streamline and ramp up production capacity.
The automaker delivered about 480,000 Model Ys in China in 2024 – up about 5% year-over-year.
It makes sense. Over the last few weeks, Tesla has basically been running a pilot of production of the upgraded version, which is entirely different from the previous version, but there are enough differences that new parts and processes can create bottlenecks.
Tesla likely found ways to optimize production during that time and now will implement it during this extended shutdown.
We will try to keep track of the Model Y production and rollout in China as any delay or production issues can be extremely impactful, considering the Model Y is the world’s best-selling EV and China is the biggest EV market.
Any kind of issue there can be extremely impactful on Tesla and the broader EV market.
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American Honda shared a business outlook for 2025 during a recent briefing with the media. In terms of electrification, the next 12 months for Honda will be much of the same: facelifting tried-and-true ICE models like the CR-V and Passport. However, there was one exciting piece of news from Honda on the BEV front—the automaker has confirmed it will begin US production of an Acura RSX EV.
Honda and its premium sub-brand Acura, for that matter, are getting more and more coverage on Electrek’s homepage thanks to the combined efforts in adding new BEV models… although that transition has still been relatively slow compared to other OEMs.
Nevertheless, Honda launched the all-electric Prologue, which has found quick success with US consumers. Shortly thereafter, Acura launched the ZDX, which sits atop the same Ultium platform as Prologue, provided through a partnership with GM.
Honda has since backed out of that partnership—at least the part where GM provides vehicle architecture—and has been developing its own in-house platform that will one day power its new 0 Series lineup of BEVs. These originally debuted at CES 2024 and remerged at this year’s event as prototypes—and now they’re white! They will also feature a new proprietary vehicle OS called ASIMO (more on that below).
While we await the arrival of those Honda BEVs, we can expect to see a new Acura model hit the market first, based on an SUV called the Performance EV Concept, which debuted at Monterey Car Week this past August. At the time, the Acura Design Studio described the concept as “the evolution of Acura’s performance-focused design direction and the brand’s next all-electric model.”
That new production model didn’t have a name yet, but we did learn it would be the first BEV to debut on Honda’s new bespoke platform and the first all-electric model to roll off its assembly lines at the new Honda EV Hub in Marysville, Ohio.
Today, we learned that the Performance EV Concept has evolved into a full-fledged passenger model with a familiar name – the Acura RSX EV.
Acura brings back the “RSX” nameplate as an EV SUV
During a media briefing earlier this week, American Honda shared its 2025 outlook, led by vice president of sales, Lance Woelfer. This year’s strategy includes the production of its first original BEV in Ohio using domestically and globally sourced parts as a new hybrid model and several ICE vehicles (boo).
Woelfer confirmed that the first bespoke all-electric model coming out of Ohio will be the Acura RSX EV. This move marks the return of a notable nameplate in the Acura lineup that evolved from the original Honda Integra. The Acura RSX was sold in North America from the early- to mid-2000s and still has a decent fanbase, especially amongst fans of the Honda Integra and Japanese Domestic Market (JDM) enthusiasts.
Acura revived the Integra nameplate in 2021 as a Honda Civic-based liftback, and although that model is sharp, it remains combustion, hence why Acura has revived the RSX name as an EV model. Per Mike Langel, assistant vice president, Acura National Sales.
The nameplate pays homage to the Acura RSX with its coupe-like silhouette, but it truly represents a forward-looking approach to fun-to-drive performance. Our second all-electric SUV will solidify our EV credentials even as its ICE stablemates, the all-new ADX, RDX, MDX, TLX and Integra continue to attract new buyers to the Acura brand.
The Acura RSX EV, seen in a unique camo wrap above, looks quite sleek, but I predict Integra and RSX purists may reject this new model out of the gate because it’s undeniably an SUV, not a sporty compact like the vehicle(s) it’s named after. This reminds me of when Ford introduced the Mustang Mach-E, and brand loyalists argued, “That’s not a Mustang.” Just like the Mach-E, the Acura RSX EV represents a new generation of performance models, no matter what you call it.
The new SUV also represents a massive step for Honda and its premium brand, as the Acura RSX EV will be the first model to utilize Honda’s new EV platform and its new ASIMO OS operating system introduced at CES 2025. At the time, Honda said ASIMO will constantly update its in-vehicle software via over-the-air (OTA) updates for both the digital UX and integrated dynamics controls that will allow the automaker to deliver “a personalized ownership experience that will enhance the joy of driving.”
Acura says the RSX EV is slotted to begin development testing in real-world conditions this week ahead of planned production in Ohio later this year. We plan to visit Honda’s EV Hub later this month, so perhaps we can capture some images of where this new SUV will be built or, better yet, look at the prototype up close.
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On today’s episode of Quick Charge, we look into a new study revealing that Toyota outspends all other automakers when it comes to funding climate change denying politicians and Fred accuses Elon of misrepresenting the data behind Full Self Driving (again).
We’ve also got word that the recently redesigned Tesla Model Y is being built in Giga Berlin, Hyundai’s electrified lineup is leading a record export year for the brand, and a new study says cleantech investments will beat out conventional energy production for the first time in 2025.
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!
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