The idea of Tesla Gigacasting the entire underside of a car is absolutely fantastic.

Title: Tesla Expands Gigacast Parts for EV Skateboard Production, Raising Concerns About Quality


Tesla, known for its disruptive approach to car manufacturing, is expanding its use of Gigacast parts beyond front and rear crash structures to include the entire EV skateboard. This casting technique allows Tesla to create expansive subassemblies with a single casting, eliminating the need for multiple parts. While some automakers are also experimenting with similar techniques, concerns about the quality and repairability of large castings remain. This move by Tesla raises questions about the company’s ability to handle complex production tasks.

Tesla’s Unique Approach to Car Manufacturing:

Since its inception, Tesla has approached car manufacturing in unconventional ways. From introducing the first luxury electric vehicle to using the entire world as a beta test for its advanced driver assistance systems, the company has taken a Wild West-style approach to innovation. This sets Tesla apart from established automakers who typically prioritize ease of production, repairability, and cost-effectiveness in their manufacturing processes.

Gigacast: A Game-Changing Technique:

Tesla’s Gigacast is a method that utilizes huge castings to create expansive subassemblies without the need for multiple parts. Unlike traditional car manufacturing, which relies on stamped sheets of metal joined together using structural welding or adhesives, Gigacast enables the production of complex parts in a single motion. According to Reuters, Tesla claims that it can combine 400 parts into one using this casting technique.

However, Gigacasting comes with its own set of challenges. Casting large parts requires careful consideration of factors such as the alloy used, cooling methods, and the design of the casting mold. As highlighted by reports of cracks on the front of a Tesla Gigacast Model Y, repairing a large casting is significantly more difficult compared to traditional stamped metal parts.

Feasibility and Industry Trends:

While Tesla’s Gigacast method has raised concerns about quality and repairability, it remains an intriguing and potentially feasible technique. Other automakers are also exploring similar casting techniques due to the reduced cost, lighter weight, and simplified production process they offer. Smaller cast structural parts, such as the cast aluminum strut towers found in Porsche 718 and 911 models, are already common in automobile manufacturing.

Tesla’s Quality Concerns:

Despite Tesla’s reputation for pushing technological boundaries, concerns about quality persist. The company has faced challenges in handling simpler production tasks, which raises doubts about its ability to effectively implement complex manufacturing processes. As Tesla pushes the boundaries of innovation with its expanded use of Gigacast parts, it remains to be seen whether the company can deliver the quality and reliability expected by customers.


Tesla’s decision to expand the use of Gigacast parts for EV skateboard production has sparked both excitement and skepticism within the automotive industry. While this casting technique offers potential benefits in terms of cost reduction and simplified production processes, concerns about quality and repairability are valid. As Tesla continues to disrupt the industry with its unconventional approach to car manufacturing, the company must address these concerns to maintain the trust and confidence of its customers. Only time will tell whether Tesla’s ambitious expansion of Gigacast parts will prove to be a game-changer or a potential stumbling block for the company.

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