Hyundai is now incorporating “hypercasting” into its electric vehicle (EV) production, echoing Tesla’s Giga Casting technique. As reported by Korean newspaper Hankyung, hypercasting involves injecting molten aluminum alloy into molds to shape the vehicle’s frame, a process Tesla first adopted in 2020 in its Fremont Factory and later in its China and Germany plants.
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Hypercasting’s distinct feature is its capacity to produce larger vehicle parts than what’s typical in the auto industry. This leads to notable benefits like saving time and resources and reducing vehicle weight. In fact, Tesla’s use of Giga Casting has reportedly reduced production costs by around 30%.
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For context, traditional methods are labor-intensive, requiring the drilling of thousands of holes into nearly 70 steel plates that are then welded individually. Hypercasting offers evident efficiency and cost benefits in comparison.
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Hyundai, having successfully introduced EVs like the IONIQ 5 and Kona Electric, understands the importance of evolving in a fast-paced EV market led by brands like Tesla. They’re strategically adapting their production and aim to be in the top three global EV producers by 2030. This includes planning to launch 31 EV models under Hyundai, Kia, and Genesis, as part of their commitment to an electrified future.
