The entire automobile industry will undergo a metamorphosis on account of gigacasting or megacasting. Tesla started the trend using large-scale die-casting in automobile industry. Dozens of chassis pieces were combined into one entire section for its model Y in 2020. The company used Giga Press equipment from an Italian supplier. The whole process curtails the number of welds and bolts and reduces weight. Megacasting machines are massive and apply 9000 tons of force upon the molten aluminum alloys within a casting mould. The punched out panels are larger and weigh 200 kg. apiece. The whole assembly process is rethought and reconfigured. It requires upfront investment. While Tesla pioneered gigcasting with their model Y, other makers are catching on recognizing its potential to revolutionize car manufacturing.

The change in production process changes the economics of the automobile industry. There could be a reduction of 20 per cent in traditionally stamped and joined body parts type cars by 2030.

The current car making process is modular, but it allows easy repairs. In a collision case, the whole burnt was borne by the front and rear bumpers sticking out from the chassis. In low-speed accidents, there was little structural destruction. The rest of the car was immune to damage. A few parts were required to be replaced. It could be done in a few hours.

In a gigacast car, repairs are costly and complicated. Large sections of the car are affected.

Modern cars are computers on wheels. There are levels of autonomy available on cars. Sensors and software have been deployed on the cars. There are rear cameras. In an accident, a car’s electronics get affected. The electronics is built into panels, doors, bumpers, fenders and the trunk. A car after accident is examined to analyze all the sensors and controllers to check what is damaged. The damaged components are replaced and recalibrated. It is an expensive and time-consuming process.

Even gigacasting does not make a car foolproof. There could be cracks in aluminium castings on models (such images could be seen online).

There are costs involved in repairing large sections. It is complex too. Industry groups and insurers are concerned. Gigacast cars may attract more premiums.

A new industry can come up — an industry to refurbish car and then sell them. It is on account of replacement (rather the repairs) that the whole car becomes brand new. Automotive recycling can become a big industry.