Toyota Demonstrates New Gigacasting Technology for Electric Vehicles

Toyota, known for its commitment to quality and efficiency, has recently showcased its new gigacasting technology for electric vehicles (EVs) at its Myochi plant in Japan. This innovative manufacturing process allows for the creation of larger and more complex vehicle parts, resulting in a significant reduction in the number of components needed and a shorter production time.

The adoption of gigacasting technology is a significant step for Toyota, which has been relatively slow in embracing electric vehicles compared to its competitors. However, the company recently announced its ambitious goal of producing 3.5 million EVs per year by 2030. To achieve this target, Toyota recognizes the need for advanced manufacturing techniques that can streamline production and reduce costs.

During the demonstration, Toyota showcased the pouring of molten aluminum into a mold, resulting in a single piece that constitutes the entire rear third of a vehicle chassis. This process, known as gigacasting, replaces the traditional method that requires 86 parts, 33 steps, and several hours of production time. With gigacasting, the same portion of a car can be produced in just three minutes.

The efficiency and speed of gigacasting are made possible by the use of large-scale molds and advanced casting techniques. Toyota has been refining its gigacasting technology since building its first prototype in September 2022. The company aims to achieve 20 percent higher productivity than its competitors through this innovation.

Toyota plans to employ gigacasting in the manufacturing of the front and rear sections of an upcoming electric vehicle scheduled for release in 2026. By utilizing this technology, Toyota aims to create EVs that are not only more cost-effective but also have improved performance and durability.

In addition to gigacasting, Toyota is also focusing on optimizing its factory operations to accommodate the production of EVs. As EVs require more factory space than internal combustion vehicles, Toyota is looking to minimize the use of conveyor belts and make its production lines more efficient.

To achieve this, Toyota plans to leverage its advanced technology and the indoor operability of EVs. Partially built vehicles will move at a slow speed to meet autonomous robots that can lift and transport them to different areas of the factory. This approach eliminates the need for extensive conveyor systems and allows for a more flexible and adaptable production process.

While Toyota may be considered a latecomer to the electric vehicle market, the company is determined to catch up and surpass its competitors. Kazuaki Shingo, Toyota’s chief production officer, stated that the company is learning from specialized EV makers and embracing new options to meet the challenge of producing high-quality and efficient electric vehicles.

With its commitment to innovation and efficiency, Toyota’s adoption of gigacasting technology represents a significant step forward in the production of electric vehicles. By reducing the number of components and streamlining the manufacturing process, Toyota aims to create EVs that are not only environmentally friendly but also cost-effective and reliable.

As Toyota continues to refine its gigacasting technology and optimize its factory operations, the company is positioning itself as a major player in the electric vehicle market. With its reputation for quality and reliability, Toyota’s entry into the EV space is sure to make a significant impact and contribute to the ongoing transition to sustainable transportation.