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GW Celebrates... the Tesla Giga Casting

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In this series of articles,  GW celebrates great products that use great castings. This month it is the turn of the Tesla Giga Casting.

370 fewer parts, 10% mass reduction, 14% range increase.

Well that's a pretty good list of step change benefits. All achieved by developing a new alloy and turning a not-so-humble aluminium casting in to a game changer for the design of car structures. Who would have thought of casting half a car in one go?

It's the sort of step change that Cosworth did 40 years ago with a new casting process. It also happens to be the sort of technical challenge that Grainger and Worrall takes on all the time in sand casting technology - material development, part count reduction, vehicle light-weighting, dimensional conformance.

This shows what you can do when you understand the fundamentals of a manufacturing process and then challenge the accepted boundaries.

Musk is reshaping the art of the possible through casting innovation. Now where have we heard that before?

Take a look at this 7 minute clip at his outdoor unveiling in 2020 where he explains the parallels with aircraft wing design, the advances in materials, and how the battery tray is now an integral part of the structure of the vehicle, ""I think that long term any cars that do not take this architecture will not be competitive".

 

 

And then maybe have a look around some of the neat stuff on our engineering page.