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Luca Greco

@lucagrecoita • 9,464 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 now weighs approximately 60 kg, down from 67 kg on the previous generation. Much of the industry conversation centers on press size and tonnage. The concrete gains in speed and mass on this high-volume part come from targeted process refinements inside the die and across the production system. -> Processing time reduced from 180s to 75s on the rear casting -> Part weight lowered by 7 kg through incremental design improvements -> Faster cycle achieved while improving microstructure and mechanical properties Conformal cooling makes the difference. Complex water channels, drilled or through 3D-printed inserts directly into the die steel, target hot spots and pull heat out rapidly and evenly across the entire casting. This accelerates solidification, reduces temperature gradients, and allows the part to be ejected sooner without defects. The result is a casting that is both lighter and stronger, produced in less than half the time. Supporting elements include advanced software that controls every injection parameter and runner/gate designs refined through five years of iteration since 2020 + close collaboration among casting designers, die engineers, production, and safety teams running high-volume lines on three continents. Tesla’s manufacturing edge is not the Giga Press hardware itself. It is the accumulated knowledge of how to run these machines at scale. 📊 The Gigacasting Database gives you the full picture of the market: 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: 📬

Tesla cut its Gigacasting processing time from 180 seconds to 75 seconds — nearly 60% faster 🌊 The Model Y Juniper rear casting now weighs approximately 60 kg, down from 67 kg on the previous generation. Much of the industry conversation centers on press size and tonnage. The concrete gains in speed and mass on this high-volume part come from targeted process refinements inside the die and across the production system. -> Processing time reduced from 180s to 75s on the rear casting -> Part weight lowered by 7 kg through incremental design improvements -> Faster cycle achieved while improving microstructure and mechanical properties Conformal cooling makes the difference. Complex water channels, drilled or through 3D-printed inserts directly into the die steel, target hot spots and pull heat out rapidly and evenly across the entire casting. This accelerates solidification, reduces temperature gradients, and allows the part to be ejected sooner without defects. The result is a casting that is both lighter and stronger, produced in less than half the time. Supporting elements include advanced software that controls every injection parameter and runner/gate designs refined through five years of iteration since 2020 + close collaboration among casting designers, die engineers, production, and safety teams running high-volume lines on three continents. Tesla’s manufacturing edge is not the Giga Press hardware itself. It is the accumulated knowledge of how to run these machines at scale. 📊 The Gigacasting Database gives you the full picture of the market: 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: 📬

169,989 görüntüleme

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 görüntüleme

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 görüntüleme

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

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 görüntüleme

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🚨 Big win for Gigacasting repairability! Renowned YouTuber JerryRigEverything broke down the full Gigacasting repair after a brutal tow hitch failure test on his Tesla — 10x the rated tongue weight. This modular approach slashes repair costs and proves large-scale aluminum castings can be practical also on the consumer side. Full article: Video source: JerryRigEverything on YouTube

🚨 Big win for Gigacasting repairability! Renowned YouTuber JerryRigEverything broke down the full Gigacasting repair after a brutal tow hitch failure test on his Tesla — 10x the rated tongue weight. This modular approach slashes repair costs and proves large-scale aluminum castings can be practical also on the consumer side. Full article: Video source: JerryRigEverything on YouTube

107,011 görüntüleme • 1 ay önce

🚨 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 🔥

370,927 görüntüleme • 6 ay önce

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

845,518 görüntüleme • 2 yıl önce

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

111,081 görüntüleme • 4 ay önce

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 görüntüleme • 1 yıl önce

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 görüntüleme • 5 ay önce

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.

36,541 görüntüleme • 5 ay önce

🇷🇺 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 görüntüleme • 1 yıl önce

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

77,783 görüntüleme • 2 yıl önce

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