Tesla will use an all-in-one die-casting machine to produce the Model Y

Tesla is preparing several major manufacturing changes in its Model Y production program, including the introduction of a large die-casting machine that can assemble most of the Model Y's frame into one large piece, according to foreign media reports.

Earlier this year, Tesla CEO Elon Musk said tesla would use aluminum castings in its Model Y car body design instead of stamped steel and aluminum parts. "When we introduced the large casting machine, we were able to turn 70 parts into one, so the robot didn't have to put so many pieces together, which greatly reduced the cost."

Now, Tesla has published a patent application that shows it is using a new casting machine to build the Model Y. The patent is titled "Multi-directional Unibody Casting Machine for a Vehicle Frame and Associated Methods."

Tesla described the current problems with the die-casting process for vehicles: "In general, during frame production and die-casting, different die-casting machines are used for different parts of the frame. For example, a single die casting machine in a factory is used to die cast a single frame assembly. Each die-cast component is then assembled or fastened together (e.g. by welding) by a factory worker or robotic system to form a frame (e.g., a one-piece frame). "The die casting process is usually very expensive compared to other casting and production processes that assemble individual components, such as due to the high cost of casting equipment and metal molds. Therefore, there is a need to improve the die casting machine and associated die casting methods, in particular to reduce the die casting work required to assemble the final frame."

Tesla has come up with a system that allows several convex dies to converge in one center. According to the patent application, the system was designed by Tesla's "head of mold manufacturing" Matt Kallas, who later left Tesla to become a die casting designer at GF Linamar.

The patent states: "The multidirectional die casting machine based on the current frame configuration consists of a die with a vehicle cover and several convex dies that can be translated relative to the cover die. These convex dies are moved to the central casting area of the casting machine and are responsible for the casting of different parts, doing most of the frame casting work in one machine."

According to Tesla, the design can "reduce production time, operating costs, production costs, plant floor space, plant operating costs, tool costs, and equipment numbers." In addition, Tesla even said it could reduce the number of casting machines needed to produce the frame and produce a "whole or partially complete" frame itself.