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What everyone was waiting for was for Italians to make the huge casting press so that castings could be done in mass production at automaker margins.


Except it was Tesla that went to the Italian casting press manufacturer and the made it a project together. Tesla asked for the biggest they had and asked for bigger and basically bought 5 years of machines, allowing them to do the necessary investment. And Tesla also used its own internal materials team to develop alloys to optimize the process to make it practical for high volume production lines like Model Y.


Despite Tesla's boastings, large casting machines have existed before. Automotive use is the new part.


What's actually new and interesting here is the combination of size and speed. Sure casting existed, but for it to be the backbone of a super fast production line like that of a Model Y, they needed to do a lot of work.

Larger parts were often dipped into liquid, because air cooling resulted the part bending.

Tesla internal materials team worked on new alloys to improve this, while working in coordination with the machine manufacture to get up the cycle times.

And they are continuing to work with them. Tesla is using newer more advanced cooling systems in Texas then they did in the California factory. Because cooling is one of the limiting factors in Cycling these machines.


Essentially it was question casting of this size being automated at car maker scale. Bigger castings were integrated before on assembly lines, but at higher costs and complexity before Italians made the large mostly automated caster that Tesla called GigaPress (iirc) - it's essentially COTS factory equipment.




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