China, September 8, 2025
News Summary
Dongfeng has finished construction of a 47,000 m² gigacasting factory 25 days ahead of schedule, allowing earlier equipment installation and commissioning. The single‑phase building will house ultra‑large die‑casting lines including a 16,000‑tonne unit and a 10,000‑tonne unit, positioning the company at the forefront of large‑format casting. Using Building Information Modeling (BIM) sped coordination and delivery. The project targets phased production capacity with an initial annual output goal of 200,000 components and a later scale‑up to 600,000 after additional lines are added. Investment is about 1 billion yuan and lines will be brought online gradually.
Dongfeng completes 47,000 m² gigacasting plant 25 days early; mass production set for June 2026
What happened: A large die‑casting plant built for an automaker was finished 25 days ahead of schedule. The facility covers about 47,000 square meters and will form the main production base for the automaker’s gigacasting program. Construction started in November 2024 and the factory building was completed in one phase, with casting lines to be installed and brought online in stages. Full mass production is expected to begin in June 2026.
Why this matters
The plant will host two very large integrated die‑casting lines in its first phase: one using a 16,000‑tonne machine and one using a 10,000‑tonne machine. These are among the largest die‑casting machines in use and are intended to produce big, single‑piece structural parts such as rear floor assemblies and battery casings for new energy vehicles (NEVs). Once running, the lines are expected to lift production speed and reduce the number of separate body parts and welds needed, which can lower cost and save factory space.
How the project was built so fast
The construction team applied Building Information Modeling (BIM) to streamline design coordination and on‑site work. The use of BIM helped identify clashes, coordinate trades and speed up the handover process, allowing the building to be turned over nearly a month before contract deadlines. The physical plant is complete; the casting equipment will be installed over time under a two‑phase plan.
Phases, cost and capacity
The total investment for the project is around 1 billion yuan. In the first phase, the plant will add one 10,000‑tonne line and one 16,000‑tonne line. That initial setup gives the site an annual capacity of about 200,000 components. A second phase will add four more lines, taking total annual output to roughly 600,000 components once complete.
What gigacasting is and why firms use it
Gigacasting uses very large die‑casting machines to make multiple vehicle parts as a single structural component. Molten metal is forced into a die under high pressure, cooled, ejected and trimmed to make a big part in one step. The approach can cut the number of parts and welds, shorten assembly lines, reduce labor and save space. It can also improve structural strength and crash performance when parts are designed correctly. Typical target parts include large underbody sections and battery trays.
Industry context
Several automakers and suppliers have moved to one‑piece die‑cast parts for EVs, citing weight reduction, lower part counts and cost savings. Some factories already use large die‑casting presses to form rear or front underbody sections. The move to ever‑larger machines aims to combine more sections into single pieces and speed up production cycles. Suppliers of prototype molds and sand test molds have been used to speed design checks and reduce validation costs during the switch to large‑scale die casting.
Tradeoffs and challenges
Big cast parts can change repair processes and collision economics: damaged cars may be harder or more expensive to repair at the part level. Large machines have high up‑front costs and require special alloys, tooling and process control to avoid distortion and casting defects. Design, testing and heat treatment processes are being adjusted by casting specialists to handle these challenges.
Next steps for the plant
With the factory shell complete, equipment installation and commissioning will follow. The first two lines are slated to be installed in the initial phase, feeding the planned 200,000‑unit yearly output capacity. Additional lines will be added later to reach the full 600,000 annual capacity. Mass production of gigacast components is planned to start in June 2026.
Photo and announcement note
The construction group that announced completion included a photo with the notice. The announcement credited the construction team’s digital planning tools as key to finishing early.
FAQ
Q: What is the size of the new plant?
A: The completed factory building covers approximately 47,000 square meters.
Q: When did construction start and when is mass production expected?
A: Construction began in November 2024. Mass production is expected to start in June 2026.
Q: What casting machines will the plant use?
A: In the first phase the plant will install a 16,000‑tonne and a 10,000‑tonne gigacasting line. More lines are planned in a later phase.
Q: How many parts can the plant make each year?
A: Phase one gives an annual capacity of about 200,000 components. After phase two adds four more lines, capacity should reach about 600,000 components per year.
Q: Why use gigacasting for EV parts?
A: Gigacasting can reduce part count and welds, cut assembly time and cost, save factory space, lower weight and improve structural performance when parts are properly designed and validated.
Q: What are the downsides?
A: Drawbacks include high initial investment, tougher repairability for large single pieces, and technical challenges in alloy and process control to avoid defects or distortion.
Key features at a glance
| Feature | Details |
|---|---|
| Factory size | 47,000 m² |
| Construction timeline | Started November 2024; building finished 25 days early |
| Key tech used in construction | Building Information Modeling (BIM) |
| Installed lines (phase 1) | One 16,000‑tonne and one 10,000‑tonne gigacasting line |
| Phase 1 capacity | 200,000 components per year |
| Full capacity (both phases) | 600,000 components per year |
| Planned start of mass production | June 2026 |
| Estimated investment | Around 1 billion yuan |
Deeper Dive: News & Info About This Topic
Additional Resources
- Reuters: Tesla Shanghai plant starts Model Y production with new cost‑cutting methods
- Wikipedia: Gigacasting
- CNEV Post: Tesla Shanghai produces Model Y with integrated die‑casting
- Google Search: Dongfeng gigacasting plant
- CleanTechnica: Let’s go gigacasting
- Google Scholar: gigacasting electric vehicle
- InsideEVs: Tesla reportedly makes one‑piece giga‑casting breakthrough
- Encyclopedia Britannica: die casting
- Gasgoo Auto News: China auto industry (gigacasting project)
- Google News: gigacasting
Author: Construction NY News
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