Toyota Motor Corporation is making a strategic move to adopt gigacasting technology, a manufacturing technique that has proven successful for Tesla in reducing electric vehicle (EV) production costs. The company plans to install a large gigacasting machine at one of its Japanese plants by the end of this year.
This initiative reflects Toyota’s commitment to enhancing EV efficiency and competitiveness. Gigacasting, a process utilizing massive machines to create large vehicle modules by merging multiple components using molten aluminum alloy injected under high pressure, offers several advantages. By molding multiple components in one step, EV makers can reduce vehicle weight and boost production efficiency.
The gigacasting machine, manufactured by Japanese company Ube Machinery, will be one of Japan’s largest, delivering a clamping pressure of 9,000 tonnes. It will be located at a production center in Aichi prefecture. For comparison, gigacasting machines generally exert at least 6,000 tonnes of force.
Toyota’s implementation of gigacasting is set to begin with the LF-ZC, a next-generation Lexus EV scheduled for launch in 2026. Initially, the gigacasting machine will be used for prototyping EV components, allowing Toyota to evaluate the technology’s potential for reducing parts, streamlining processes, and resulting in lighter EVs.
Toyota’s decision to adopt gigacasting aligns with its broader strategy to reinvest profits from its successful hybrid business into EV development, aiming to catch up with global competitors. The company is joining a growing trend, as over 10 companies worldwide, primarily in the U.S., Europe, and China, have adopted gigacasting. Notably, Tesla utilizes gigapresses with clamping pressures between 6,000 and 9,000 tonnes. Honda has also deployed a 6,000-tonne gigacasting machine at a research facility in Tochigi, while Nissan plans to install a similar machine by fiscal 2027, with the goal of reducing component weight by 20%.
Toyota’s move into gigacasting marks a significant shift in its approach to EV production, signaling its commitment to staying competitive in the rapidly evolving electric vehicle market.
