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Luca Greco

@lucagrecoita • 9,272 subscribers

Reindustrializing ⚙️ Working in high pressure die casting 🏭 Gigacasting and magnesium market analyst 📊

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Tesla cut its Gigacasting processing time from 180 seconds to 75 seconds - nearly 60% faster 💡 The Model Y Juniper rear casting weighs approximately 60 kg, down from 67 kg on the previous generation - a 7 kg reduction through incremental design improvements. But the processing time improvement is the real story. How? Conformal cooling. Complex water channels drilled or 3D-printed inside the die steel cool hot spots rapidly and evenly across the entire casting. This accelerates solidification, improves microstructure, and improves mechanical properties. The result is a casting that is lighter, stronger, and produced in less than half the time. Add to that: -> Close collaboration between casting designers, die designers, production team and safety team -> Engineering teams from 3 continents, all running Gigacasting in very high volume -> Advanced software controlling every injection parameter -> Optimized runner and gate design refined through five years of iteration since 2020 Tesla's manufacturing advantage isn't the Giga Press itself. It's knowing how to run it - and having five years of compounding process knowledge that no competitor can shortcut. 🎞️ Credit: Atomic Industries - Aaron Slodov ❌ Don't leave your insights to chance with the X algorithm ✅ Subscribe for free to my weekly newsletter about all things Gigacasting and magnesium Thixomolding: 📬 📊 The Gigacasting Database:

Tesla cut its Gigacasting processing time from 180 seconds to 75 seconds - nearly 60% faster 💡 The Model Y Juniper rear casting weighs approximately 60 kg, down from 67 kg on the previous generation - a 7 kg reduction through incremental design improvements. But the processing time improvement is the real story. How? Conformal cooling. Complex water channels drilled or 3D-printed inside the die steel cool hot spots rapidly and evenly across the entire casting. This accelerates solidification, improves microstructure, and improves mechanical properties. The result is a casting that is lighter, stronger, and produced in less than half the time. Add to that: -> Close collaboration between casting designers, die designers, production team and safety team -> Engineering teams from 3 continents, all running Gigacasting in very high volume -> Advanced software controlling every injection parameter -> Optimized runner and gate design refined through five years of iteration since 2020 Tesla's manufacturing advantage isn't the Giga Press itself. It's knowing how to run it - and having five years of compounding process knowledge that no competitor can shortcut. 🎞️ Credit: Atomic Industries - Aaron Slodov ❌ Don't leave your insights to chance with the X algorithm ✅ Subscribe for free to my weekly newsletter about all things Gigacasting and magnesium Thixomolding: 📬 📊 The Gigacasting Database:

114,027 Aufrufe

Tesla's Giga Berlin expansion confirmed: 500,000 to 800,000 annual capacity 🏭 In July 2025, Tesla confirmed an expansion of Giga Berlin that will add 2 million square feet of factory space. This boosts annual production capacity from 500,000 to 800,000 vehicles, with provisions for in-house battery cell production. In December 2025, Tesla announced plans for new local battery cell production by 2027. The rear underbody Gigacasting at Giga Berlin consolidates what were previously 70 individual parts into a single large aluminum casting. By late 2025, the factory is operating on two shifts to meet demand, exporting Model Y vehicles to over 30 markets globally. ❌ Don't leave your insights to chance with the X algorithm ✅ Subscribe for free to my weekly newsletter about all things Gigacasting and magnesium Thixomolding: 📧 📊 The Gigacasting Database:

Tesla's Giga Berlin expansion confirmed: 500,000 to 800,000 annual capacity 🏭 In July 2025, Tesla confirmed an expansion of Giga Berlin that will add 2 million square feet of factory space. This boosts annual production capacity from 500,000 to 800,000 vehicles, with provisions for in-house battery cell production. In December 2025, Tesla announced plans for new local battery cell production by 2027. The rear underbody Gigacasting at Giga Berlin consolidates what were previously 70 individual parts into a single large aluminum casting. By late 2025, the factory is operating on two shifts to meet demand, exporting Model Y vehicles to over 30 markets globally. ❌ Don't leave your insights to chance with the X algorithm ✅ Subscribe for free to my weekly newsletter about all things Gigacasting and magnesium Thixomolding: 📧 📊 The Gigacasting Database:

98,931 Aufrufe

The Rear Gigacasting on the New Model Y has been Redesigned • 7kg lighter or -10.8% • 50% less machining • Cycle time 70 sec vs 170 sec or -55% According to Lars in a clip from Munro Live below

The Rear Gigacasting on the New Model Y has been Redesigned • 7kg lighter or -10.8% • 50% less machining • Cycle time 70 sec vs 170 sec or -55% According to Lars in a clip from Munro Live below

110,959 Aufrufe

Xiaomi Super Factory 🏭 Looks familiar? The Xiaomi SU7 is outselling the Tesla Model 3 in China and Xiaomi’s next model, the YU7, is a direct competitor to the Model Y. For the YU7 Xiaomi is installing new 9,100t Giga Presses in addition to the 2 operational ones.

Xiaomi Super Factory 🏭 Looks familiar? The Xiaomi SU7 is outselling the Tesla Model 3 in China and Xiaomi’s next model, the YU7, is a direct competitor to the Model Y. For the YU7 Xiaomi is installing new 9,100t Giga Presses in addition to the 2 operational ones.

27,596 Aufrufe

SERES Unveils Magnesium Gigacasting for Mass Production 🏭 At the SERES Intelligent Safety Conference during the Shanghai Auto Show on April 23, SERES debuted the world’s largest magnesium alloy rear Gigacasting designed for mass production. Developed in collaboration with Baowu Magnesium, and other partners, this magnesium underbody component transitions magnesium alloy rear underbodies from laboratory prototypes to full scale vehicle integration and mass production. 🪶 Compared to traditional aluminum alloy solutions, this casting achieves a 21.8% weight reduction. Gong Jianyong, Vice President of AITO, highlighted that AITO models currently incorporate over 10 magnesium alloy parts, totaling 20 kg per vehicle, positioning SERES at the forefront of the Chinese automotive industry. While the part is now in production, vehicles equipped with these magnesium components are yet to reach customers. It remains unclear whether this is for a new model or an upgrade to SERES’ existing lineup. AITO was originally a join venture between Huawei and SERES, but last summer SERES acquired all the shares and patents.

SERES Unveils Magnesium Gigacasting for Mass Production 🏭 At the SERES Intelligent Safety Conference during the Shanghai Auto Show on April 23, SERES debuted the world’s largest magnesium alloy rear Gigacasting designed for mass production. Developed in collaboration with Baowu Magnesium, and other partners, this magnesium underbody component transitions magnesium alloy rear underbodies from laboratory prototypes to full scale vehicle integration and mass production. 🪶 Compared to traditional aluminum alloy solutions, this casting achieves a 21.8% weight reduction. Gong Jianyong, Vice President of AITO, highlighted that AITO models currently incorporate over 10 magnesium alloy parts, totaling 20 kg per vehicle, positioning SERES at the forefront of the Chinese automotive industry. While the part is now in production, vehicles equipped with these magnesium components are yet to reach customers. It remains unclear whether this is for a new model or an upgrade to SERES’ existing lineup. AITO was originally a join venture between Huawei and SERES, but last summer SERES acquired all the shares and patents.

23,171 Aufrufe

$Isn’t it crazy? This is a semi molten aluminum slurry at ~50% solid fraction It looks like cold slush 🍧 but it’s hot af 🎞️: Casting-Campus GmbH$

Isn’t it crazy? This is a semi molten aluminum slurry at ~50% solid fraction It looks like cold slush 🍧 but it’s hot af 🎞️: Casting-Campus GmbH

10,239 Aufrufe

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🚨 BREAKING: Volvo officially becomes the first European OEM to adopt Tesla style Gigacasting The Volvo EX60 rear underbody uses an 8,500 T die casting machine 🔥

🚨 BREAKING: Volvo officially becomes the first European OEM to adopt Tesla style Gigacasting The Volvo EX60 rear underbody uses an 8,500 T die casting machine 🔥

370,767 Aufrufe • vor 4 Monaten

This video is the perfect example of one of Elon Musk's most famous quotes: “The most common error of a smart engineer is to optimize a thing that should not exist” Elon Musk In the first part of the video we can see robot arms seam sealing the chassis of a car, which is a common process for cars made with hundreds of stamped sheets welded together by thousands of welds. This is for protecting the car against corrosion and leaks This was marketed as “seamless perfection” and as an “innovation” But what is really happening is that engineers spent countless hours optimizing a process that SHOULDN'T EXIST! Why?! Because a car underbody made with only 2 pieces using Gigacastings eliminates thousands of hyper optimized micro and macro processes and save companies space, time, labor and ultimately thousands of $$$ per car Just like the Model Y, the Cybertruck and Tesla's future vehicles It is no coincidence that OEMs and suppliers around the world have purchased over 180 Giga Presses to imitate Tesla Elon's quote is from Everyday Astronaut Starbase tour video

This video is the perfect example of one of Elon Musk's most famous quotes: “The most common error of a smart engineer is to optimize a thing that should not exist” Elon Musk In the first part of the video we can see robot arms seam sealing the chassis of a car, which is a common process for cars made with hundreds of stamped sheets welded together by thousands of welds. This is for protecting the car against corrosion and leaks This was marketed as “seamless perfection” and as an “innovation” But what is really happening is that engineers spent countless hours optimizing a process that SHOULDN'T EXIST! Why?! Because a car underbody made with only 2 pieces using Gigacastings eliminates thousands of hyper optimized micro and macro processes and save companies space, time, labor and ultimately thousands of $$$ per car Just like the Model Y, the Cybertruck and Tesla's future vehicles It is no coincidence that OEMs and suppliers around the world have purchased over 180 Giga Presses to imitate Tesla Elon's quote is from Everyday Astronaut Starbase tour video

845,238 Aufrufe • vor 1 Jahr

Dongfeng's 16,000-ton Gigacasting machine just entered production - the largest die casting machine ever built 🏭 It is now producing battery trays. For scale: before 2018, a "large" die casting machine was 4,000 tons. Tesla raised the bar to 6,000 tons for the Model Y in 2020. Then 9,000 tons for the Cybertruck. Now Dongfeng is producing at 16,000 tons. Four times the pre-Gigacasting standard. At this tonnage, Dongfeng can cast integrated chassis and battery tray structures in a single shot - components that require multiple machines and assembly steps at any other OEM. The evolution in 7 years: -> Pre-2018: 4,000T (industry ceiling) -> 2020: 6,000T (Tesla Model Y) -> 2023: 9,000T (Tesla Cybertruck) -> 2026: 16,000T (Dongfeng, in production) No Western machine is operating above 9,000 tons today. March 25-28th I will be in Wuhan, China where I will see this 16,000 T machine If you want to follow my trip, foIIow me on Instagram, I’ll post stories of the factory and event

Dongfeng's 16,000-ton Gigacasting machine just entered production - the largest die casting machine ever built 🏭 It is now producing battery trays. For scale: before 2018, a "large" die casting machine was 4,000 tons. Tesla raised the bar to 6,000 tons for the Model Y in 2020. Then 9,000 tons for the Cybertruck. Now Dongfeng is producing at 16,000 tons. Four times the pre-Gigacasting standard. At this tonnage, Dongfeng can cast integrated chassis and battery tray structures in a single shot - components that require multiple machines and assembly steps at any other OEM. The evolution in 7 years: -> Pre-2018: 4,000T (industry ceiling) -> 2020: 6,000T (Tesla Model Y) -> 2023: 9,000T (Tesla Cybertruck) -> 2026: 16,000T (Dongfeng, in production) No Western machine is operating above 9,000 tons today. March 25-28th I will be in Wuhan, China where I will see this 16,000 T machine If you want to follow my trip, foIIow me on Instagram, I’ll post stories of the factory and event

110,992 Aufrufe • vor 2 Monaten

A 2-year study just proved Gigacasting repairs can cost LESS than traditional bodies 💡 Thatcham Research conducted a rigorous study on Tesla Model Y repairability. At 15 km/h impacts: Crash cans absorbed energy. Gigacasting sustained zero damage. Standard repair. At 25 km/h impacts: Casting cracked. Full replacement required. The replacement casting costs just £716. Total repair bill? Comparable to - sometimes cheaper than - traditional steel structures. The data: -> Model Y partial repairs: £2,167 CHEAPER than Model 3 repairs -> Model 3 uses traditional steel subframe -> The "unrepairable" casting was more economical The repair myth isn't based on evidence. It's based on 2021 assumptions the industry has solved. ❌ Don't leave your insights to chance with the LinkedIn algorithm ✅ Subscribe for free to my weekly newsletter about all things Gigacasting and magnesium Thixomolding: 📩

A 2-year study just proved Gigacasting repairs can cost LESS than traditional bodies 💡 Thatcham Research conducted a rigorous study on Tesla Model Y repairability. At 15 km/h impacts: Crash cans absorbed energy. Gigacasting sustained zero damage. Standard repair. At 25 km/h impacts: Casting cracked. Full replacement required. The replacement casting costs just £716. Total repair bill? Comparable to - sometimes cheaper than - traditional steel structures. The data: -> Model Y partial repairs: £2,167 CHEAPER than Model 3 repairs -> Model 3 uses traditional steel subframe -> The "unrepairable" casting was more economical The repair myth isn't based on evidence. It's based on 2021 assumptions the industry has solved. ❌ Don't leave your insights to chance with the LinkedIn algorithm ✅ Subscribe for free to my weekly newsletter about all things Gigacasting and magnesium Thixomolding: 📩

94,749 Aufrufe • vor 4 Monaten

After Tesla introduced Gigacastings in 2020, many Chinese OEMs adapted quickly and immediately introduced the technology This is how the rear gigacastings for Huawei’s AITO M9 are made 👇🏼 (awesome footage) 🎞️: Dongguan Daseon

After Tesla introduced Gigacastings in 2020, many Chinese OEMs adapted quickly and immediately introduced the technology This is how the rear gigacastings for Huawei’s AITO M9 are made 👇🏼 (awesome footage) 🎞️: Dongguan Daseon

281,665 Aufrufe • vor 1 Jahr

Xiaomi delivered 550,000 vehicles in 20 months. And every single one uses Gigacasting. In 2020, Tesla pioneered Gigacasting. By 2024, Xiaomi was already in mass production - with self-developed alloys and now has 6 machines running at full capacity. But Xiaomi isn't alone. Here's what my database shows: → Xpeng launched 4 new Gigacast models in just 2 years → Seres (AITO) uses Gigacasting on ICE vehicles - not just EVs → Tesla still leads in process reduction, but Chinese OEMs are catching up fast I've built a side-by-side comparison of Tesla vs. three Chinese OEMs: Xpeng, Xiaomi, and Seres. It covers: - When each started Gigacasting and how they scaled - Machine sizes, suppliers, and production volumes - Design philosophy: why the castings are the way they are - Vertical integration vs. outsourcing tradeoffs This is the data behind the headlines. Want the Tesla vs China Gigacasting Comparison? 1. Connect with me 2. Comment "GIGA" below I'll send you the report. PS - Repost for priority access.

Xiaomi delivered 550,000 vehicles in 20 months. And every single one uses Gigacasting. In 2020, Tesla pioneered Gigacasting. By 2024, Xiaomi was already in mass production - with self-developed alloys and now has 6 machines running at full capacity. But Xiaomi isn't alone. Here's what my database shows: → Xpeng launched 4 new Gigacast models in just 2 years → Seres (AITO) uses Gigacasting on ICE vehicles - not just EVs → Tesla still leads in process reduction, but Chinese OEMs are catching up fast I've built a side-by-side comparison of Tesla vs. three Chinese OEMs: Xpeng, Xiaomi, and Seres. It covers: - When each started Gigacasting and how they scaled - Machine sizes, suppliers, and production volumes - Design philosophy: why the castings are the way they are - Vertical integration vs. outsourcing tradeoffs This is the data behind the headlines. Want the Tesla vs China Gigacasting Comparison? 1. Connect with me 2. Comment "GIGA" below I'll send you the report. PS - Repost for priority access.

36,510 Aufrufe • vor 4 Monaten

🇷🇺 Russian drone manufacturer says Starlink is the only western system making a difference in the war “Honestly Starlink is the Holy Grail” Andrea Stroppa 🐺 Claudius Nero's Legion 🐺 🎞️: Real Reporter /YT

🇷🇺 Russian drone manufacturer says Starlink is the only western system making a difference in the war “Honestly Starlink is the Holy Grail” Andrea Stroppa 🐺 Claudius Nero's Legion 🐺 🎞️: Real Reporter /YT

59,515 Aufrufe • vor 1 Jahr

Ex Tesla director of body repair program, John Sweigart about Tesla’s engineering and the competition Special guest: The Cybertruck 📐 🎥: Evolve: Electric Vehicle Specialists /YT link below

Ex Tesla director of body repair program, John Sweigart about Tesla’s engineering and the competition Special guest: The Cybertruck 📐 🎥: Evolve: Electric Vehicle Specialists /YT link below

77,692 Aufrufe • vor 1 Jahr

Inside Giga Shanghai’s die casting shop It’s interesting to notice that it has Tesla’s only fully automated Gigacasting production line worldwide $TSLA

Inside Giga Shanghai’s die casting shop It’s interesting to notice that it has Tesla’s only fully automated Gigacasting production line worldwide $TSLA

19,813 Aufrufe • vor 1 Jahr

Tesla is investing massively into its aluminum supply chain for Gigacastings I doubt we'll see magnesium Gigacastings from Tesla by 2030 even if thanks to Alex Grant it becomes available in the US Optimus, on the other hand, has a lot of potential for magnesium content $TSLA

Tesla is investing massively into its aluminum supply chain for Gigacastings I doubt we'll see magnesium Gigacastings from Tesla by 2030 even if thanks to Alex Grant it becomes available in the US Optimus, on the other hand, has a lot of potential for magnesium content $TSLA

17,387 Aufrufe • vor 1 Jahr

Gigacastings + Unboxed process reduces the Paint Shop size by 70%! 😳 It’s not Tesla saying this $TSLAQ According to Mr. Vachaparampil, Caresoft Global CEO Source: Autoline

Gigacastings + Unboxed process reduces the Paint Shop size by 70%! 😳 It’s not Tesla saying this $TSLAQ According to Mr. Vachaparampil, Caresoft Global CEO Source: Autoline

13,390 Aufrufe • vor 1 Jahr

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