The Incredible Logistics Of The Tesla Giga Press!
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- Опубликовано: 6 авг 2024
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The Incredible Logistics Of The Tesla Giga Press!
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Please remark on how Project Highland, in integrating a front casting into the Model 3, is the final stage of giga cast development, pending Gen3. Also, despite their low run rates, will S, X, & even Roadster ever justify giga casting? Could that be part of the Gen3 evolution? Finally, given the need for secrecy, will it be another year or so before we see similar graphics about Semi? Thx for your outstanding content!
@The Tesla Space - the primary reason for high ductility in Aluminium for Automotive, is for safety. You can't have crumple zones with a brittle metal that will shatter. That's the main reason the industry avoided Aluminium for the frame. Another related reason as been that Aluminium is prone to "work hardening" which means that stresses it experiences during its operational life make it less and less ductile, leading to failure via cracking. So the same problem in a few years. "Aircraft grade" Aluminium alloys are focused on preventing work hardening, because aircraft flex a lot. That's also why Aluminium bicycle frames are generally made from "aircraft grade" alloys.
A significant other would be the perfect gift for me...
If the whole car is made out of one big casting, how is it repaired? In a regular car you simply replace tha damaged parts, but that´s not an option if the whole car is just one piece.
In the 50 60s the factories tried cast frames. Problem was they totalled the car after small crash because welding and straightening
are not possible. So insurance companies stopped it as to costly. They had concerns of crash and crush zones. Mostly for the cars they hit. The giant piece does not release energy by bending twisting and crumpling. The forces of a sqaure battery pack is like a kinetic missile at 70 mph. The body on skateboard design showing cases of the sled and pack sheering off from body in crashes with firetrucks. The bottom flew right under the truck frame and top was crushed.
As an ex racer and tester of AutoCAD in 90s we resorted to the roll cage and crumple zones.
Frame should be square stainless steel box tubing hydro bent and robotic welded. Steel
is essily recycleable and cheap.
You have pointed out a major vulnerability, there goes your social credit score. 😢
Talk about living in the past. Go back over the Munro Podcasts and pay attention to the design developments from here beyond 2021 . They have cast an amazing repairable substructure that is rated by ANCAP to five stars of Safety, that pretty much says it all …
The press power capabilities are many folded.
The key power needed is injection force, since the flow will encounter cooling when pressure released inside the tooling (moulding), injection must be completed within very short time.
The power required is usually referred to the injection pump.
In the above footage, the creative new idea of having two set of injection directions at an angle of 90⁰ to each other. This is to going after a multiple insert effect.
The objective of having double inset is a common practice.
However, the injection heads directions may not be fixed 90⁰ at each other.
Rule of thumb is, the main product generated has to be injected and finished in one go. The odd structures hindering mould pair opening can be solved by multiple small inserted half moulds at strategy positions, even the injection paths can be coming from different sides, from different injection pump route.
J
Therefore, the extra adjunct injection head setup is depending on finished product design.
"While Henry Ford is often credited for creating the assembly line, he did not. He merely improved and innovated on it. He found the idea for the assembly line from another Michigan based automobile company run by Ransom Olds."
Generally, in academia, the assembly line's credits go back to Taylor (Frederick Winslow Taylor (1856-1915) was born in Philadelphia, Pennsylvania): "The term Fordism ... refers to the rationalization of the Taylorist method of organizing work through the creation of assembly lines, which made standardization and mass production possible. The advantage of the assembly line was that it brought the work to the worker instead of making the worker go to the work."
"Frederick Taylor’s four principles of Scientific Management are:
1 Develop a science for each element of work
2 Scientifically Select, Train, Teach, and Develop the worker
3 Cooperate with the Worker
4 Divide the Work and Responsibility"
One of the best videos I’ve seen on RUclips …. Really interesting, thorough, well put together. I’d like to see you get more views than you have so far…..I don’t know whether you’ve considered making more noise on Twitter, but there’s a massive Tesla community on there and I think you would get millions of hits for a video of this quality. I haven’t seen anything else like it. Just a thought…
Tesla has received a 9000 ton Giga Press in Shanghai. The 9000 ton Press was made for the larger castings of the CT. There is no plans for the CT to be produced in Shanghai. So what’s the huge 9000 ton press for? To cast the complete frame for the new Model 2 of course 😅
My father made a line of cast aluminum safety products. One thing to consider about using such large castings in an automobile, is that you can't repair cast parts; you typically have to replace them, and if they are making such huge castings it means that fender-bender body shop costs will be staggeringly high.
Aluminum is a soft metal. THere's a very good reason why Steel has been used for so long. It selectively deforms, and is very repairable. So these cars are more of a disposable product. I would be more comfortable if they made various modules and riveted them together so you could replace say the rear right section of the car body. Tesla cars average over 2200/year in insurance costs (and can be as high as 4k in some jurisdictions). What is the point of saving fuel with an EV if your insurance costs wipe out the savings?
Great video! Short answer is NO. They will likely be able to cast an entire floorpan, or symmetrical halves, but an entire car body (or substructure/frame) simply has too many closed off nooks, crannies and sectional shape changes to make in one casting. A die has to displace all volume you don't want metal, and there is no way to do that and get the die(s) back out of the car. Watch videos on how engine blocks are cast using lost wax (or foam) to sand and you'll see why die casting can't do that. Still, Giga press are awesome and will make ever larger single piece front, rear or section halves of a car/truck that are welded together or connected with easy to make cross pieces...
What's interesting to me is that the casting industry was so limited in clamp force and size while the injection molding industry has had machines in the 6000T scale for a while.
nobody wanted them, so why build them.
Great video - loving the facts, science, and technology re what *casts* Tesla into a league of their own.🙌💯
Facts hardly
@@luvelyjubely how are they NOT facts, if it's stating quite literally the reality of what happened?
@@ivant5054 ooooh we have a musk stan
How do these huge parts affect repair costs after car accidents.
Will a small accident be a total loss. What would the insurance repercussions be of this.
It would be great if someone did a video on the repair ability of such parts and manufacturing techniques
It’s the frame. If the frame gets bent on any car it is salvaged.
The body of a tesla is not what I would worry about in an accident, the battery pack is whats going to cost the most to replace. Repairing a badly damaged unibody on a vehicle is a common practice these days.
@@leebatt7964 reassembling the complete car in another body is more expensive than company production.
@@littlebrothermoneywithmich6178 nonsense, a lot of accident cars with damage to frame get repaired, and not all of them are bad, some are, but there are a lot of shops who do quality work on 50+k$ accident cars, but with this new teslas build method it might not be possible any more, aluminum behaves different than steel, a torn off bracket or missing piece could be welded back in no problem, but that is small stuff, if a side sill is bent, then it will most likely mean a write off, not the most eco friendly option... cheap to make though
With regard to the castings of an entire vehicle, it seems the two halves would need to be the right and left halves of the vehicle running lengthwise. Kinda like what appears on Tesla’s investor day promotional image everyone is sleuthing over. The two halves would be connected widthwise by the structural battery pack. The size of the battery pack could be altered by its length ( to a degree) if necessary. The drive unit would couple the rear together. The steering unit would couple the front halves together. Steering units (right hand/left hand) depending on the country, could be interchangeable. Can’t wait for March 1st.
The downside is that's an increase in projected area, which requires much more clamp force on the tool.
That's likely not viable with the current gigapress.
I think people have learned never to bet against EM, no matter how seemingly outrageous the goal may be.
I suggest there is no reason why Tesla won't continue on its skyward trajectory of innovation and permanently leave all others in the dust. Fantastic!
Gigapress is an outdating technology in China, otherwise China will not let this factory export his technology to IDRA, even this Italian factory is a subsidiary.
China's military jets frames are no longer using these high tonnage press, they have migrated to 3D unibody metal printing, the superpress technology is no longer military grade!
@@liwenhu5864 you are confusing many applications here
first and foremost, SpaceX pioneered in the usage of metal 3D printing a while back, for parts of the merlin engine, so they are plenty familiar
the problem with metal 3d printing is that it's SLOOOOW, haven't you ever seen a 3d printer working?!
the Chinese military has shifted only the high end jets to 3d printed frames, like J20s, which won't be produced at high volumes
for the rest regular casting will still be used
May be. But I think that Tesla will go through different steps- first one have been made, front and rear castings. I think next one could be the body sides castings that could be attached to the front and rear casting with acommodations for the floor casting, so may be not a single casting but just four or five castings that could be joined together. Tesla have already the concept of the Triangle for a Truck structure in the Cybertruck, maybe they could follow something similar for the smaller, less expensive car first, and then apply that for the single casting car, producing an extremely strong and robust vehicle never seen before!!!!!
Good explanatory video, with one caveat. The casting is neither doused nor later heat treated. Early Model S castings were doused and they distorted slightly and had to be worked on, so Tesla material science developed an alloy which didn't need it for the Model 3/Y castings. Therefore greater accuracy and fewer processes. Elon Musk explains this in an interview with Sandy Munro on the Munro LIVE YT channel.
I wonder if they need a bit of time to settle down after casting so they put them in racks and move them outside for a couple of days as we see at the giga factory. Maybe surface oxidation or rinse off the peanut oil/ removal.🤔
@@malcolmrickarby2313 They just need a cooling down time, so inevitably a cooling batch is produced where the first example is cool enough to be used and the latest hot one adds to the batch. Under such conditions, there's no waiting.
Making a single die cast for the whole frame is already in the "hot wheels" concept (at 4:29). It will require a central collapsable piece (for the cast to be removed from the press) with at least 4 giga press devices. Maybe more than 4 and then a two or more stages to accomplish the final product (frame).
Tesla makes science fiction more reality than fiction.
Solid video man,I didn’t know the Press needed more clamping force just to make a BIGGER part. I thought it was to make a more complex part.
The press power capabilities are many folded.
The key power needed is injection force, since the flow will encounter cooling when pressure released inside the tooling (moulding), injection must be completed within very short time.
The power required is usually referred to the injection pump.
In the above footage, the creative new idea of having two set of injection directions at an angle of 90⁰ to each other. This is going after a multiple insert tooling effect.
The objective of having double inset is a common practice.
However, the injection heads directions may not be fixed 90⁰ at each other.
Rule of thumb is, the main product generated has to be injected and finished in one go. The odd structures hindering mould pair opening can be solved by multiple small inserted half moulds at strategy positions, even the injection paths can be coming from different sides, from different injection pump route.
Therefore, the extra adjunct injection head setup is depending on finished product design.
Good unique IDRA footage which I have never seen before. Good work.
They will absolutely accomplish an entire vehicle in a single casting, it might be smaller than the 3 but it will happen. Imagine a small vehicle in the cyber truck concept as a compact utilitarian vehicle without paint. Low cost, durable, and unbeatable at that price point.
Yes please! Hard to imagine that they won’t crack it considering their progress over the last few years
If you knew anything about casting it is impossible due to angles and draft angles and die manufacture.
@@dikkybee4003 I’m sure you are smarter than Sandy Munro but he discusses these Giga Presses at length and bottom line is Tesla innovations in many areas is giving them an advantage that won’t soon be surpassed if ever by the competition.
@@purchasedbyblood have you ignored the whole "more advanced castng machine than anything the industry has" part?
guess who the only one here who has no clue is
More important is that they get their quality control and reliability in check cause they are always near bottom in those rankings . But that would be a good step forward
great video. ultimately the wiring will be included in the casting. the efficiency march is relentless!
I love TTS, but...(Nit: If you're going to say and print the word "whoa", please at least spell it correctly.) Thank you for yet another stimulating and fascinating look at life in the Tesla space.
I didn't know they had designed their own alloys as well. Isn't there another possible 12,000T Giga Press for the Cybertruck?
I can see the front structure, floor pan and rear structure cast as one piece. I propose that the battery pack and belly pan be attached to the floor pan with an array of through bolts that clamp the two pans and the batteries into a composite structure. I can see a platform for raising the battery pack up to the bottom of the floor pan with an electric driver for each nut nut on the bottom of each through bolt. Zimmmmmmm! Done and torqued.
14:00 rearview mirrors not scale.
another great video by The Tesla Space, because as always you succinctly make the points while also entertaining along the way.
Great video. Full floor pan casting is probably the limit of economics and practicality
My forecast is that the first model 2 will be assembled from 2 giga castings using the 9000 tn press, which are fastened directly together front to back with just reinforcement with the structural battery pack. That way the basic frame could be assembled almost as soon as they come off the press, after trimming.
what about longevity of those castings in colder climates where they use lots of salt on roads during winter? and what about collision repair?
Doubt going from 2 castings and a couple of rails (for the rigid battery pack) to 1 single casting would be useful. You can make front and rear strong enough to survive anything but a crash that would total the vehicle anyway. Not so sure for a casting that ran the length of the vehicle cast in aluminum alloy. Would prefer the laterals to be steel for better side impact resistance which would also help to protect the cabin and battery.
Also you are talking of replacing 4 parts with 1. Not 70:1. Not a big game changer that will eliminate another 300 robots or even 30.
I'd be more interested in seeing all his cars have both front and rear castings.
The patent pending for development request for funding is a single manufacturing machine that can change the density of lesser metals into a superior quality there by reinforced in doing so can do the very thing in a simpler design and has way more versatility across more production line variations of size and scale
Great ! Tesla i so neat! and also that little micro current device- Bear! defintitely looking into it!
I’m still really interested in what the crash rating will be with a single casting, or the damage to another vehicle and it’s occupants
Why? The model y with single and dual castings have been out for years now. The very first model y sold in 2020 had the casting.
Munro tore one down and showed it off. The latest dual castings 4680 pack model y was torn down last year by them to.
Crash ratings for them have been available for years now.
Maybe an added 'crumple zone' or shifting passenger area for the necessary shock absorption.
I mean it would be the same more or less. Its still aluminum and they are still using crumple zones.
Great informative video. Full of useful information thanks
You missed the biggest plus to castings. The bolt pattern is no longer .032 of an inch. With CNC mills, any pattern can be accurate to plus or minus .002 inches within 3 standard deviations using center drills instead of spot drills and a dedicated single step machine can generally hold .005 inches. That allows all the parts to fit together with fewer rejects. Rejects use up space, time, and they are product that generally can't be sold.
Finally someone that is talking about post machining on the die castings. I have to wonder how much machining will have to be done. I've worked in two different die casting shops as a mold maker and I am always amazed at how ignorant people are to the ability of a die casting. Any threaded holes, motor mounts and suspension points will have to be machined in a precision manner . This idea of taking a raw casting and just gluing it into place is just stupid. That is unless Elon plans on making an even more shabby product. 😢
@@paul5683 Aluminum face mills very quickly these days, though the mills that I have worked that size run 3 million each plus tooling. I would think that shrinkage would be the bigger problem, but you are the casting person.
Shrinkage is figured in to the dimensions of the mold by making all dimensions larger in the mold, you can plan on what you will end up with. Everything has a shrink factor, usually taken care of with using a percentage multiplication. Distortion in the ejection and cooling process is also an issue with a big casting like that, often not something you can see until you try machining it.
Congrats on reaching 300,000 subscribers. Excellent results for an excellent channel.
A vehicle formed in a single casting, would look like the upper body casting of a Hotwheels car. The under body would be a second casting with the structural battery pack being relying on it for its base and sides, and the suspension/brakes/transmission/engine(s)/thermal management/aircon/wiring harness would be components received by it. So the "car" would be the upper body, dropped onto the electric skateboard. That electric skateboard might be used between multiple different models, varying entirely in the upper body casting, and in the fitments.
I'd start with a Roadster 1.5, a long overdue refresh. Casted into 1 piece. I'd try 2 of the 1st smaller presses set side-by-side. One cast. Multiple injection ports. Make a full casting. Add injector ports for other parts.
Make this Roadster a modernized improvement. Hold off on the SpaceX rocket version for Roadster 2.0.
The speed of gigapresses means bottlenecks in production will be much slower. One set of gigapresses can provide more than one model line. This has implication to the design of the factory floor.
Remove some more robots and create space for more lines in an already gigantic factory.👍🏽
All of this is exactly correct, let me briefly describe how bad that is.... A small fender bender totals the car, the unibody is unrepairable or non serviceable, there are some clever people developing techniques but for some unknown reason, Tesla will not discuss spare parts or replacement parts. i'm okay with the notion of disposable unserviceable cars but they need to be dirt cheap.
Only the frame is die cast, if you bend a fender, you can replace it, just like on any other car.
@@Ronan1701 the unibody is the frame.... it is unserviceable and unrepairable. the fronk lid, trunk lid, doors, fenders and bumpers are the only replaceable parts
11:56 Just a note from someone living in Australia. Salted roads aren't the only environment that is hostile to corrosion. If you live close to the ocean, like most Australians, salt is a big problem.
13:54 YES! not tomorrow, but absolutely YES!! If they were able to figure out how to press a half a car, it is only a matter of time before they figure out how to do the whole thing.
Entirely possible to make the body in two parts (excluding doors, trunk etc.)
3:29 references SPOT ON😂😂🔥
The past tense of cast is cast, not casted.
I feel sorry for the other die casting machine manufacturers. Just think of the massive free advertising IDRA have now had over these Giga presses. They're going to be the single go to company for anyone looking to replicate what Tesla have done. I bet IDRA were only known about in the die casting world, and being Italian probably not all of it. Now the whole world knows about them by people outside this industry. That opens up possibilities for engineering solutions where die cast operations were not even considered.
Where were they not considered? all industries besides the car sector of industry?
The world of high-cost industrial process equipment is WAY different from the dollar-store retail market which you describe.
Any company looking to produce alum castings will stumble over IDRA first, regardless of the efficiency of their purchasing dept.
Based in Italy but Chinese owned. Which is why they agreed to build a press double they have ever previously made.
@@kimollivier haha that’s exactly what I was going to say. IDRA is owned by a Chinese company called “LK Machinery”. So technically Tesla is landing deals with the Chinese.
@@MohrRacing2that is not new, Teslas whole business plan has been buying inexpensive Chinese manufacturing products. Cheap Chinese punch press dies, fixtures, robots, plastic molds, plastic molding machines, die cast dies and all the way to the now famous Idra casting machines all purchased under value from China. Good old Chinese "dumping".
The concept shown at 13:40 looks great!
12:08 😃
What happens when someone crashes and needs a new part? Is there a plan to cut and weld/bond sections back in?
Tesla aren't interested in that. Their right to repair is shocking. They'll just want to sell you a whole new car. It'll be the iPhone of the car world. And their fans will lap it up
Worked with an ex engineer who did work for Tesla on their chassis, he said the model 3 is a joke, Tesla is a tech company trying to be an automotive manufacturer. He said their designers would ask for stupid/ignorant requests because they didn’t know what they were doing. From a ME with a PE. The trouble with making something one piece is it’s one piece, what’s the cost to replace the frame if it gets damaged?
Sandy never said that the battery and packs were “next level”.
If I remember correctly, it was the power-management and the chips.
lol the annealing process is not to collapse bubbles in the structure XD u gotta give accurate info brotha
Yeah, they said that Cybertrack will be made not casting but bending - so it's for MY or M2)
thats the exo-frame not the structural components
Problem with the Cyber Truck is the design leaves much to be desired for a pick up truck. Can't side load it, for starters. The Rivian is a superior design for not just aesthetics, but as a pickup truck in general - it's a lot more functional with details for daily use - more stuff, less fluff.
Innovation illuminates inefficiencies you didn't know you had. Well done.
that was a awesome video with lots of facts!
I'm just concerned about collision damage repairs. Also, what is the projected failure-rate on the aluminum structure itself and the electric motor and battery combination? Are we talking a 200,000-mile automobile, or something far less than that?🤔
I believe if Tesla used a 7 part Mould with multiple Injectors they could produce a full Frame Section in just one shot.
The giga press and the alloy is like when they had to come to work steel to build taller buildings that needed to flex.
One press car casting? Im not sure if making a car in one press is necessary since the speed they make model Ys is already incredible. You can always add another press to increase volume
WhaT heat treatment releases stress in the metal. Not porosity. In no way does it remove this
The Machine that builds the machine…. Project Highland. 😎
The Giga Press is awesome. What Teslas also can do, in my humble opinion, is to mount the hinges of the moving parts (doors, trunk and boot) 'Lego' stile. This way the panel gaps can all but disappear. Ever tried to press two Lego blocks screw together?
THIS MACHINE!!! PORNO! for Me!!
at "Only 57" and retired but Journeyman Millright, Industrials Controls Haz Locations Electrician, Hydraulics Tech, Fueling Tech, Alt Energy RnD, Pipe Fitter, Carpenter, Plumber, Teamster, Glazier?
I LOVE ELON!! and How He Works! I would Sign ON "Just for" the Ride! and the Show in a MOMENT!! Elon is Going to Change our World for Better!
I was working in Foundries and Forges at 12 yrs old, helped Dad built the Western World Larget Ring Roller in the 80's in Paramount Ca. helped my older Bro develop binders for sand casting and continuous mixing in the early 80's!!
I LOVE THIS STUFF!! like a Bull Charges the Red!
Saved for integrated fasteners-
They need to get away from "metal" in frame and body.
Injection mold entirely from co-polymers & tri-polymers.
Colored built in- no more paint or coatings. Larger airbags,
fire suppressing foam where needed, 1-piece rim/solid tire wheel.
Batteries need to be made more able to be recycled.
The speed of the gigapress was my main inquiry when I first clicked on this video and answer was provided, thanks
Trying to do it all with a single cast seems like a trap. It becomes so complex when simply doing three large parts get you the majority of the simplification and cost cutting you are after anyway.
If the whole frame was built at once, ¿would the whole vehicle be disposable after any of its sections is bend/damaged in a crash?. For instance a small crash may bend the right-rear. ¿Could that be fixed?
yes, reparability is not always a priority when trying to increase efficiency
another example, older tesla battery packs can have individual modules replaced at an independent shop (Tesla would just tell you buy a 20k usd new battery), but with the structural battery there is no option for reparability
there are always 2 sides to the coin
Buy a new car 😂
But if the car has an accident isnt it more expensive to replace a part if there is only one big part?
But with their unitary design will a evident repair be more difficult, expensive and increase insurance costs?
In an accident that totals the car, it wouldn’t matter. However, if not totaled, it is designed to have the crash absorbers cut off and new ones bolted on.
Yes what's else with Tesla anything is possible! Excellent video ✔️ Nichola approved
R
so pretty much a 5mph vender bender is a totaled car now! Just like when the battery drops below 50% life, you basically buy a new car (or at least nearly as much) Maybe when they get to be $5,000, it could actually work and just be a throw away car! lol.
One part replacing 70 parts means 69 parts were removed from the vehicle.
robots gonna strike: "dat damn giga press...it stole our jerbs."
Thanks for the research
Interesting, it reminds me when I was working in plastic injection company here in Taiwan 2yrs ago.
I missed working in plastic injection as machine ops.
Many follow-on stories now are needed. Elon claims that his patents can be used by VW, Ford, General Motors, Toyota, etc. Will they do this?
The model 3 will now be resigned to become a one piece gigacast?
Current car manufacturing, the Henry Ford style, with human labor instead of almost total automation, is now extinct?
Can the China brands (Byd, etc) also now use gigacast machines?
Does Tesla use industrial glue and spot welding? How much less of this do they do?
Operating the Tesla still requires user maintenance. How much is automated, prompting the user? How much is eliminated completely, or severely limited?
We are assuming that some maintenance requirements still need user attention? Cleaning the windows and dust and dirt?
The corrosive resistant metals forced an new type of paint. Is that a Tesla patent and necessary requirement that makes normal painting and maintenance not work so well?
Which of these Tesla changes to machine development be moved to other manufacturing industries, to other products, and to other brands? Failure to follow Tesla advanced will make which brands to collapse? Toyota, who refused to be totally EV? General Motors, who had so much brave claims and daring intentions, but unrealistic deadlines and deliveries?
What a time
Those other 4 companies that turned the opportunity to be game changers of the 21st century Industrial Revolution… will go down as the ‘Decca Records’ of the industry!
(Decca turned down The Beatles in 1962, because ‘guitar groups are on the way out., and more ironically; “the Beatles have no future in show business.”)
For the younger people, think of Blockbuster Video, who turned down buying Netflix, which then went on to destroy their entire business model.
I'd like to see how the Giga Press could handle FRP instead of aluminum. I predict plastic of sore sort will eventually be used for the entire frame, if not the entire body in white.
For a while, Starship was going to be made in Carbon Fibre, but the SpaceX team ditched that idea and went with Stainless Steel.
Maybe but its not as simple as manufacturing it. There are all kinds of regulations and safety tests that would have to be met. That said, if anyone can do it, Tesla would be my pick. They are amazing in what they do. SpaceX and Tesla both. As a 65 year old the differences between the mid 60s and now are almost unbelievable. Almost magic. I picked 60s because that's all I can remember. Crazy.
Always remember that aluminum is easily recycled and polymers are not.
A little off the Giga Press topic, but this intrigues me. Let's think a little further into the future. What would a vehicle (probably autonomous) be made of if it is explicitly designed not to crash? And let's take that one step further - what about if all vehicles on the roads are eventually replaced by those that can't crash? What are they made of? 100% recyclable bio-plastic?
If they did it with a Hot Wheels vehicle then yes it can be done. It's just a matter of time. Now they have to develop the press that'll allow them to do that. They can also 3D print it.
I see your thinking, but hotwheels aren't full working cars. They can be solid metal. Nevertheless I think single piece casting or something close to it will happen sooner or later. Tesla has been pressing forward with everything quite agressively and succesfully and will with this too.
@@thotmorgana you can't assemble everything you want to go. You know your power source, motors, wheels, brakes, plastic parts, and any other miscellaneous stuff has to be assembled by a person. You're just talking about the frame pressing It can be done in one go. If you were to cast the whole thing in a sand mold yes. For instance if you were going to make a sword how would you do it it's the same concept there's just no pressure involved. Just remember when you're assembling the driving mechanism, and interior parts that has to be done by hand. You can't do that in one go. Unless you 3D print
@@1bluemoondj Yes i didn't mean assembly I just meand the parts in this case the frame. Though I wonder if it would make any benefit to have one part instead of 2 (or 3 with structural battery included). There is a company btw that fully 3d prints custom supercars. At least all the parts of the supercars and than assembles them. It is pretty cool.
@@thotmorgana to be honest with you, I'm thinking about it and it wouldn't be beneficiary because of repair. Whenever they do body repair, which I don't think many people would do on a Tesla, you have the section off parts. If you're talking about cost efficiency it may not be at the beginning but as time progress it may get to that. You might have to do a six part mold to get the vehicle to be cast correctly. About the battery structures they would have to install that afterwards. That has to be inspected to make sure everything's a line correctly. I know the car can be, referring to the frame, but I don't think the battery and the car could be done at the same time. You have to remember the car is hot when it comes off the press batteries can only take a certain amount of temperature. I think it's better to do to two to three parts. You have the main structure and then your side structures. The doors and everything has to be added later on.
Amazing engineering
I need say, this is insane! But in this situation, they will need employees? Or not because before this machine they don’t use employee in this line production?
Idra started to develop their GigaPress about 2016. In 2019 they proposed to several automotive manufacturers their new press. Several said them that they would not arrive to make it work.
Tesla instead ordered the GigaPress.
There is an Automotive News Europe about.
Other automotive manufacturers have ordered the Idra GigaPress.
The next level engineering that Tesla brings to manufacturing is mind-blowing. Step-change mind-blowing.
The next level engeneering belongs to IDRA not Tesla.
The casting machine was an excellent collaboration between the companies, I get that. Tesla’s vertically integrated manufacturing system, though - the machine that builds the machine - is step-change awesome.
@@vintagegamingrepublic5156 So according to your claim, Tesla didn't collaborate with IDRA on the design of these presses needed for the production of Tesla cars?
@@ChitFromChinola In every instance of video footage I've seen of Tesla's manufacture, I've not seen anything of suspension manufacture, wheel manufacture, gear, driveshaft and CV manufacture, brake manufacture, electric motor manufacture for seats and door closure, glass manufacture, electronic board manufacture (except for assembled in Mexico stickers), shock absorber manufacture, air suspension manufacture. How is this vertical manufacture? They look like an assembly plant to me.
The Munro Associates tear down videos are a pretty good source. From the tear downs, it looks to me like Tesla makes a lot of stuff that other companies out-source. Front casting. Rear casting. Batteries. Battery pan. Heat pump. Seats. Electric motors. I think their engineering is pretty amazing, and their level of vertical integration is much deeper than most. But if you think it’s all rather ho-hum, you’re probably right. I’m not an automotive engineer, and Sandy Munro is probably full of it, so you go . . .
There is a second company making these giant casting machines, Bühler from Switzerland. Their top model "Carat 920" has a clamping force of more than 9300 metric tons.
Great video, supreme idea of manfactoring the key component..... One but what happens after a crash if the base is damaged, you can't weld it together, can you
Just like the 747. Boeing didnt want to build it because no civilian airports were big enough to handle it and the cost to build it was absurd but the airlines promised to buy it if Boeing built it, the airports grew to accomodate it, and the rest is history.
6:26 something falls from the cast.
Amazing
does Tesla have only one CT gigapress? redundancy hello?
You did it; I wasn't sure if you'd mention the al/li recipe for the giga-press, but you did & even broke it down to basics.
Good job!
I agree that while the Cybertruck should provide great off-road and on-road performance...utility will probably be an area of compromise.
I think the utility will surprise you. The durability alone will make it a better work truck.
@@danharold3087 Charging Electric Vehicles is annoying tho. At least at my company, Every EV will need a dedicated parking spot with a dedicated charger. So at the end of the day, you can park it and forget it until the EV is needed again. Gas trucks can be refueled in minutes. Companies can't lose time waiting for vehicles being refueled. So,, every work truck needs a dedicated ev parking spot. That is prohibitive for most companies.
@@currentsupply You're looking for why it will not work. The accounts will look at cost savings and if they can make a strong case it will go with EVs. Saving on maintenance alone may pay for the needed chargers. When each truck has its own charger you will save that trip past the gas pump. Checking the oil etc.
FUD spreaders have you thinking that it will always take a long time to charge a truck. This is typical of their tactics. Charging times are going down.
"According to New Scientist, research conducted at the Idaho National Laboratory can charge EV batteries from a 0% state of charge to 90% in 10 minutes, equating to a 60% decrease in charging time compared to current Supercharger times"
If your thinking all battery claims are pie in the sky realize that the current battery has 8X the capacity of batteries of 10 years ago. This advance is what makes the Tesla Semi workable with a 500 mile range.
No, the doors, frunk lid, trunk lid and floor will always be cast separately.
But, I can see where innovation may speed up the cast process and expedite the assembly process.
The Giga press is a fantastic piece of equipment. Kudos!
Additionally, Idra needs to expand to meet the demands of Tesla's competitors. Maybe a factory in Chile ?
So what happens when this uni-frame automobile has a relatively minor crash, such as a rear-ender that bends or wrinkles a small area of the vehicle? Can it be repaired, or does the entire vehicle have to be scrapped?
...ask Mr. Musk...
My thoughts exactly.
I’m a tow truck driver, basically if you get in a relatively normal collision… your cars totaled.. if your battery needs replaced, totaled
Fantastic video. Thanks 😊
How about *REPAIRABILITY* ? Does having a single piece make body and frame repairs harder?
Cybertruck has an exoskeleton of stainless steel plate, so why would it need castings?
The best part is no part. . . until things need repair.
Awesome
Sounds good, but how to fix a car after a minor crash? Change the whole piece which only Tesla can manufacture?
is model 3 now built by giga press?
It seems like you should talk about how these castings affect the people who buy the cars. The engineering processes and utility of these castings are only as good as the experience they provide the end user. Clearly Tesla would have thought about this but what is the result? If a Tesla is in a crash, can you take it to a panel beater? If not, can Tesla invent panel repair processes for minor damage that even Tesla can allow 3rd parties to repair? For bigger damage do you need to throw away the car and get a new one since you can't replace small sections of the body?
Not touching on these things suggests that they are problems without good solutions.