Tesla achieves breakthrough in single-piece car casting, report says
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.
However, Tesla has already pushed the limits of casting technology to be able to produce the rear and front casting on Model Y and had a new 9,000-ton press made to produce Cybertruck parts.
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.
Tesla had an interesting patent on that technology back in 2019.
I still think this should be taken with a grain of salt, but I wouldn’t be surprised if it turns out to be true.
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China’s Contemporary Amperex Technology Co., Limited (CATL) has unveiled its latest battery cell technologies, which charge as quickly as filling up a gas tank while potentially lowering costs without compromise.
CATL has quickly become the world’s largest battery manufacturer by a wide margin. It is one of, if not the biggest, force for advancing electric transportation.
A big part of CATL’s success is due to its advancements in lithium-iron phosphate battery cells, also known as LFP. LFP cells are cheaper than nickel-rich batteries, but they used to have much lower energy density.
The Chinese battery manufacturers managed to close the gap somewhat while maintaining lower costs, resulting in LFP cells becoming popular for entry-level EVs.
Now, CATL is looking to do the same with sodium-ion batteries.
Like LFP cells, sodium-ion battery cells have the potential to be cheaper than more common Li-ion cells, but they also offer potential for superior performance, particularly in terms of faster charging and longer lifecycles.
CATL has unveiled today Naxtra, its new sodium-ion battery cells, and it claimed some truly impressive specs.
The new cell reportedly achieves an energy density of 175 Wh per kg (385 Wh per lb), on par with the higher-end of LFP battery cells.
The new cells also offer potential for significant safety improvements.
CATL shared several intense stress tests, including drilling into a cell and even cutting it in half without any thermal event:
The next-gen sodium cells could help further lower the cost of electric vehicles without compromising performance, and while increasing safety.
On top of the new Naxtra cell, CATL has also unveiled its next-gen Shenxing LFP battery cells.
Its charge rate is truly impressive. CATL shared several examples of cars charging at around 1,000 kW and maintaining over 500 kW at over 50% state of charge:
The new cell is being described as capable of adding 300 miles (482 km) of range in about 5 minutes – depending on the EV model.
That’s virtually as quick as filling up a tank of gas.
CATL says that the Shenxing will be in 67 electric vehicle models by the end of the year.
The next-gen cell was unveiled after BYD, CATL’s biggest competitor, also unveiled its latest technology, capable of charging electric vehicles at extremely high speeds.
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New York State has announced an extra $30 million for point-of-sale rebates to lease or buy more than 60 new EV models.
The rebates are available to consumers through New York’s Drive Clean Rebate program, which offers a point-of-sale rebate off the manufacturer’s suggested retail price (MSRP) of an EV at participating car dealerships in New York State.
The rebate is available in all 62 counties, with the highest rebate of $2,000 available for EVs with a greater-than-200-mile range. (For a 40- to 199-mile range, the rebate is $1,000.) The New York State Energy Research and Development Authority (NYSERDA) runs the program.
NYSERDA President and CEO Doreen M. Harris said, “Converting to EVs reduces the total cost of vehicle ownership through lower fuel and vehicle maintenance costs, and NYSERDA is proud to help provide New Yorkers with more purchasing power through these rebates.”
The Drive Clean Rebate program has issued over 190,000 rebates to consumers since 2017, contributing to the more than 280,000 EVs on the road in New York State.
NYSERDA also boosted its EV charging incentives. Through the Charge Ready NY 2.0 program, the state is boosting the cash available for Level 2 charger installations at apartment buildings, workplaces, and hotels from $2,000 to $3,000 per port. And if the chargers go into disadvantaged communities, that amount jumps to $4,000 per port.
New York has racked up over 17,000 public EV chargers, making it second only to California for charger count. On top of that, there are more than 4,000 semi-public stations tucked into workplaces and multifamily buildings across the state.
Read more: New York awards $60M to Revel to install 267 DC fast chargers
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LTL carrier ArcBest Freight (ABF) announced plans to add five new Orange EV electric terminal tractors to its existing ZEV fleet, bringing its total deployment of these battery electric HDEVs to 14 … with even more to come.
LTL stands for “Less than Truck Load,” and basically means that, since whatever you’re shipping won’t take up a full container, you can share the costs of shipping with other customers with goods going the same way. You save a little more money and the shipper makes a little more money, making it a rare win-win scenario in the shipping space. And that’s important, because LTL containers amount to a massive 15% of total US shipping.
ABF has been putting Orange EV yard dogs to work in their LTL traffic terminals since their initial deployment of four trucks in June 2022. The company added five more a few years later, and just purchased five more — further underscoring their confidence in the benefits of transitioning their fleet to electric power.
“The Orange EV terminal trucks meet our operational requirements and expectations for safe, reliable, and affordable service and performance,” explains Matthew Godfrey, ABF Freight president. “We’re committed to responsible environmental management, and our investment in EVs aligns with our continuous efforts to enhance efficiency while maintaining exceptional service standards.”
ABF joins other large logistics companies like YMX and DHL in deploying the Orange EV terminal trucks, which have logged hundreds of thousands of hours of service for their customers.
Electrek’s Take
Over at The Heavy Equipment Podcast, we had a chance to talk to Orange EV founder Kurt Neutgens ahead of last year’s ACT Expo for clean trucking. On the show (embedded, above), Kurt explained how his experience at Ford helped inform his design ideology, and that the Orange EV was designed to be cost competitive with diesel options, even without subsidies.
Give it a listen, then let us know what you think of the big yard dogs in the comments.
SOURCE | IMAGES: Orange EV; via PR Newswire.
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