DUBLIN--(BUSINESS WIRE)--The "Automotive Integrated Die Casting Industry Report, 2024" report has been added to ResearchAndMarkets.com's offering.

Integrated Die Casting Research: adopted by nearly 20 OEMs, integrated die casting gains popularity.

Automotive Integrated Die Casting Industry Report, 2024 summarizes and studies the status quo of integrated die casting industry and the industry chain products layout of OEMs and suppliers, and predicts the future development trends of the integrated die casting industry.

Multiple breakthroughs have been made in the integrated die casting upstream supply chain (die casting machines, molds and non-heat-treatable materials).

Super-large die casting machine: At present, the tonnage of super-large die casting machines has been increased from 6000T to 16000T, and die casting machine suppliers are developing 20000T die casting machines.

Large die casting machines are the basis for automotive integrated die casting. Generally speaking, integrated die casting requires die casting machines with >6000T clamping force. Currently, only IDRA, Brown, Boveri & Cie, L.K. Technology, Haitian Die Casting and YIZUMI can produce 6000T die casting machines. In October 2023, L.K. Technology unveiled a 16000T super-large intelligent die casting unit, making a breakthrough in clamping force increased from 6000T to 16000T in only three years. It is the largest die casting machine in the world so far, and is expected to cover class A0-C and SUV models.

Now, Tesla, L.K. Technology and Haitian Die Casting among others have started deploying and developing >20000T die casting machines.

In June 2023, Haitian Die Casting and Chongqing Millison Technologies announced that they would jointly develop 20000T super-large die casting machines.

In December 2023, L.K. Technology and Neta Auto signed a strategic cooperation agreement on joint R&D of >20000T super-large die casting equipment to expand the application of integrated die casting to the chassis of class B vehicles.

Integrated die casting mold: At present, the self-weight of an integrated die casting mold has exceeded 250 tons.

Before 2023, in China only a few mold manufacturers such as GZDM Technology, Ningbo Sciveda Mould (SWD), and ZDM (Zhenzhi) Machinery & Mould had the capacity to produce ultra-large integrated molds. However quite a few companies including Chongqing Millison, Rayhoo Motor Dies, Chongqing Borun Mould Manufacturing and Ningbo Xinlin Mould Technology can produce super-large molds now. Although HLGY and Qixin Mould have yet to mass-produce actual products, they are vigorously making layout.

From the perspective of mold technology, significant breakthroughs have been made in R&D of integrated die casting molds. In 2019 when only having experience in producing 50T molds, ZDM (Zhenzhi) Machinery & Mould secured an order from a new energy vehicle company for a body structure mold weighing 80 tons, which was the largest mold in the world at that time. The integrated body structure die casting mold self-developed by Ningbo ZDM in May 2023 weighs 250 tons and can assist OEMs in integrated die casting of front and rear chassis. From 50T and 80T to current 150T, 200T and 250T, ZDM (Zhenzhi) Machinery & Mould has kept breaking records.

Non-heat-treatable materials: domestic manufacturers have embarked on non-heat-treatable materials by way of patent licensing, independent R&D, and cooperation with universities or automakers, accelerating localization.

The composition of non-heat-treatable materials is complex. First movers have obvious advantages. Alcoa and Rheinfelden announced their non-heat-treatable materials as early as the 1990s, while China's first entrant Lizhong Group stepped into the market in 2020. Nowadays, many manufacturers and universities in China, such as Shanghai Yongmaotai Automotive Technology, Hubei Xinjinyang, Weiqiao Pioneering, Suzhou Huijin Smart Technology, Xiaomi, Shanghai Jiao Tong University and Guangdong Hongtu Technology, have acquired non-heat-treatable materials patents by way of independent or cooperative R&D.

In August 2023, Xiaomi Automobile secured a non-heat-treatable material patent for 'Xiaomi Titans Metal', its self-developed alloy material.

In November 2022, 'Xianjing" (fiber crystal), a new non-heat-treatable high-strength high-toughness aluminum alloy material co-developed by ZEEKR and Suzhou Huijin Smart Technology Co., Ltd., officially came into production.

Application of integrated die casting in vehicle body: from rear underbody to front cabins, middle integrated die cast parts and battery trays.

Since Tesla used a 6000T die casting machine to mass-produce the rear underbody assembly for Model Y for the first time in 2020, other automakers in China such as NIO, Xpeng, Li Auto, Xiaomi, ZEEKR, AITO and Neta have also laid out integrated die casting. At present this technology has been adopted in multiple models, and finds application in front cabins and middle integrated die cast parts in addition to rear underbodies.

As of April 2024, integrated die casting had been used in mass production of rear underbodies, front cabins and middle integrated die cast parts and battery trays, as shown below:

• Rear underbody: Chinese emerging carmakers have gradually realized the mass production of integrated die cast rear underbodies for models such as NIO ET5, Xiaomi SU7, ZEEKR 009/007/ New ZEEKR 001 and AITO M9.
• Front cabin: some automakers can mass-produce front cabin components for models such as new NIO ES8 and Xpeng G6/X9.
• Middle integrated die cast parts: the middle integrated die cast parts for ZEEKR 001 FR has been mass-produced.
• Battery tray: L.K. Technology has mass-produced the world's largest integrated battery tray, which is about 2180*1500*110 in size.
• It is expected that integrated die casting will cover battery case upper cover, middle floor, and underbody assembly in 2027. Tesla, FAW and Xpeng already have plans:
• Tesla: it plans to replace the 370-component underbody assembly with 2-3 large die cast parts in 2025. The weight will be reduced by 30% and the manufacturing cost by 40%.

Key Topics Covered:

1 Overview of Automotive Integrated Die Casting Industry

1.1 Development Background of Integrated Die-casting Industry

1.2 China's Policies Concerning Integrated Die Casting

1.3 Definition of Integrated Die Casting Industry

1.4 Comparison between Integrated Die Casting and Conventional Processes

1.5 Development History of Integrated Die Casting Industry

1.6 Advantages of Integrated Die Casting

1.7 Disadvantages of Integrated Die Casting

1.8 Application of Main Integrated Die-cast Parts in Vehicles

1.8 Application of Main Integrated Die-cast Parts in Vehicles

1.9 Integrated Die Casting Industry Chain Layout

2 Key Technologies of Integrated Die Casting

2.1 Principle of Integrated Die Casting Technology

2.2 Technical Barriers to Integrated Die Casting

2.3 Key Technologies of Integrated Die Casting: Large-tonnage Die Casting Machine

2.4 Key Technologies of Integrated Die Casting: Mold

2.5 Key Technologies of Integrated Die Casting: Non-heat-treated Materials

2.6 Key Technologies of Integrated Die Casting: Die Casting Process

2.7 Other Key Technologies of Integrated Die Casting: Die Casting Simulation Technology

3 Integrated Die Casting Layout of OEMs

3.1 Tesla

3.2 NIO

3.3 Xpeng Motor

3.4 Li Auto

3.5 Xiaomi

3.6 ZEEKR

3.7 Neta Automobile

3.8 Chery

3.9 Integrated Die Casting Technical Solution of AITO

3.10 FAW's Layout and Cooperation in Integrated Die Casting Technology

3.11 Changan Automobile's Layout and Cooperation in Integrated Die Casting Technology

3.12 Great Wall Motor's Layout and Cooperation in Integrated Die Casting Technology

3.13 Volkswagen's Integrated Die Casting Technology Application and Layout

3.14 Volvo's Layout and Cooperation in Integrated Die Casting Technology

3.15 Toyota's Integrated Die Casting Technology Layout

3.16 Mercedes-Benz's Integrated Die Casting Technology Layout

3.17 Cadillac's Integrated Die Casting Technology Application and Cooperation

4 Integrated Die Casting Layout of Tier1s

4.1 Wencan Group

4.2 Guangdong Hongtu

4.3 IKD

4.4 Xusheng Group

4.5 Millison

4.6 Sunpin Technology

4.7 Asiaway

4.8 Rayhoo

4.9 Chuzhou Duoli Automotive Technology Co., Ltd.

4.10 Changqing Machinery Co., Ltd.

4.11 Friend Co., Ltd.

4.12 Other Suppliers

4.12.1 Chervon Auto Co., Ltd.

4.12.2 Jiangsu Bojun Industrial Technology Co., Ltd.

4.12.3 Jiangsu Rongtai Industry Co., Ltd.

4.12.4 CITIC Dicastal

4.12.5 Exquisite Die Casting

4.12.6 Change Technology

4.12.7 Cooperation of Ningbo Tuopu Group

5 Integrated Die Casting Supply Chain Layout

Die Casting Machine Suppliers

5.1 L.K. Technology

5.2 Haitian Die Casting

5.3 YIZUMI

5.4 IDRA

5.5 Buhler

Mold Suppliers

5.6 Guangzhou Die and Mould Manufacturing (GZDM)

5.7 ZDM(Zhenzhi)Machinery & Mold Co., Ltd

5.8 Ningbo Saiweida (SWD)

5.9 Chongqing Guangcheng

5.10 Ningbo Heli

5.11 Integrated Die Casting Mold Technology

5.12 Chongqing Borun Successfully Delivers 7000T Integrated Die-casting Rear Floor Mold for Changan Automobile

5.13 Xinlin Mold's Integrated Assembly Center for Large Die-casting Structural Parts Officially Put into Operation

Suppliers of Heat-free Materials

5.14 ALCOA

5.15 Rheinfelden

5.16 Lizhong Group

5.17 Shanghai Wantai Aluminum

5.18 Hubei Xinjinyang

6 Development Trends of Integrated Die Casting

6.1 The Tonnage of Integrated Die-Casting Equipment Will Keep Increasing and Chinese Players Gain Momentum

6.2 In 2023 Multiple Mold Manufacturers Deployed Integrated Die Casting and A Multi-leader Pattern Will Take Shape in the Future

6.3 The Technical Barriers to Non-heat Treatment Have Been Broken down and Chinese Players Acquire Ever More Patents

6.4 Emerging Carmakers Apply Integrated Die Casting in Much More Models and Conventional Automakers also Accelerate Their Layout

6.5 In the Long Run Third-party Die Casting Factories Will Dominate

6.6 The Application of Integrated Die Casting Has Expanded from the Rear Underbody to the Front Underbody, Requiring Higher Tonnage Die Casting Machines

For more information about this report visit https://www.researchandmarkets.com/r/kkcn7f

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