China, September 8, 2025
News Summary
Dongfeng has finished construction of a 47,000 m² gigacasting factory 25 days ahead of schedule, allowing earlier equipment installation and commissioning. The single‑phase building will house ultra‑large die‑casting lines including a 16,000‑tonne unit and a 10,000‑tonne unit, positioning the company at the forefront of large‑format casting. Using Building Information Modeling (BIM) sped coordination and delivery. The project targets phased production capacity with an initial annual output goal of 200,000 components and a later scale‑up to 600,000 after additional lines are added. Investment is about 1 billion yuan and lines will be brought online gradually.
Dongfeng finishes 47,000 m² gigacasting plant 25 days early; 16,000‑tonne and 10,000‑tonne lines set for mass production in June 2026
A new die‑casting plant built for a major automaker has been completed 25 days ahead of schedule, offering an early start on equipment installation and commissioning for an advanced production system that will serve electric vehicle manufacturing. The finished plant covers 47,000 square meters and is described as the core base for the company’s full gigacasting industrialization effort.
What was delivered and why it matters
The single large factory building is ready for the next work: installing two ultra‑large die‑casting lines. The first phase will house one 16,000‑tonne line and one 10,000‑tonne line. These machines are among the biggest of their kind anywhere, and the 16,000‑tonne unit marks the company as the first automaker to adopt that capacity level. Once both lines are in operation, the plant is expected to sharply increase output and production efficiency for new energy vehicle (NEV) structures such as rear floor assemblies and battery casings.
Timing and production targets
Construction of the building began in November 2024 and the structure was finished in a single phase well ahead of contractual deadlines thanks to advanced project methods. Mass production at the site is scheduled to begin in June 2026. The project is being rolled out across two phases: the first phase, with the two large lines, is designed to reach an annual capacity of 200,000 components, while a later phase adding four more lines aims to scale annual output to 600,000 components.
How the job moved faster
The construction team implemented Building Information Modeling (BIM) to speed design coordination and site work. Using BIM helped the project move quickly from handover to the point where casting lines can be installed, enabling delivery nearly a month ahead of schedule.
What gigacasting is and the expected benefits
Gigacasting uses very large machines to force molten metal into molds under high pressure so that multiple vehicle parts are cast together as one large structural piece. This method replaces dozens or hundreds of welded or joined fragments with a single module. The approach is known to strengthen vehicle bodies, simplify assembly, cut parts and robot needs, reduce manufacturing steps, and lower costs per unit. For NEVs, larger single pieces can also help integrate battery structures and improve crash performance.
Project scale and investment
The investment in the project is around 1 billion yuan. While the physical factory building is now complete, casting lines will be installed and brought online gradually rather than all at once. The plan foresees adding four additional lines in the second phase to reach the full planned capacity.
Industry context
The use of massive die‑casting machines is becoming more common as automakers look to speed EV production and lower costs. One‑piece underbody casting has been used to reduce part counts, cut weight, and replace welding operations with a single casting cycle. Several automakers have introduced one‑piece or large‑format die‑casting on current models, and other manufacturers are exploring similar moves or mixed approaches depending on model strategy and repairability considerations.
Tradeoffs and technical notes
Gigacasting brings important benefits but also challenges. Large initial equipment costs and potential metal distortion during cooling can complicate early production. Casting alloys, cooling profiles, and post‑cast heat treatments often need adaptation to meet structural and crashworthiness targets. Repair processes and collision economics change when body sections are single large castings, and some manufacturers balance these issues against the gains in speed and cost.
Next steps
With the factory building complete, the immediate focus is on installing the two headline die‑casting lines and preparing tooling and quality systems for the ramp toward the June 2026 mass‑production date. Production will begin in stages as each casting line is brought online, meeting the phased plan for capacity growth up to 600,000 components per year after full build‑out.
FAQ
What was completed early?
The factory building for a large gigacasting project was finished 25 days before the contract deadline.
How big is the new plant?
The completed facility covers 47,000 square meters.
What casting machines will be installed?
The first phase will install one 16,000‑tonne line and one 10,000‑tonne line, both described as very large for this technology.
When will mass production begin?
Mass production is expected to begin in June 2026, with lines brought online gradually.
What is the expected output?
The first phase aims for 200,000 components per year, rising to 600,000 per year after a second phase adds more lines.
Why use gigacasting?
Gigacasting can reduce part counts and welding, speed assembly, cut costs, and improve structural integration for EVs, though it introduces tradeoffs in repairability and initial capital costs.
Key features at a glance
| Feature | Detail |
|---|---|
| Facility area | 47,000 square meters |
| Main machines (phase 1) | One 16,000‑tonne line and one 10,000‑tonne line |
| Mass production target | June 2026 |
| Phase 1 annual capacity | 200,000 components |
| Full build annual capacity | 600,000 components (after second phase) |
| Project start | Construction began November 2024 |
| Investment | About 1 billion yuan |
| Construction method used | Building Information Modeling (BIM) to speed delivery |
Deeper Dive: News & Info About This Topic
Additional Resources
- Reuters: Tesla Shanghai plant starts Model Y production with new cost‑cutting methods
- Wikipedia: Gigacasting
- CNEV Post: Tesla Shanghai produces Model Y with integrated die‑casting
- Google Search: Dongfeng gigacasting plant
- CleanTechnica: Let’s go gigacasting
- Google Scholar: gigacasting electric vehicle
- InsideEVs: Tesla reportedly makes one‑piece giga‑casting breakthrough
- Encyclopedia Britannica: die casting
- Gasgoo Auto News: China auto industry (gigacasting project)
- Google News: gigacasting
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