Gigacasting – The future of automotive production and optimised post-processing with parallel kinematics

How Gigacasting is Revolutionizing the Automotive Industry

Gigacasting, also known as Megacasting, has firmly established itself as a groundbreaking technology in the automotive industry. Large structural vehicle components are produced in a single piece using aluminum die casting. This process drastically reduces the number of individual parts, lowering production costs and simplifying assembly processes. However, how can these components be precisely post-processed? This is where the combination of Gigacasting & Parallel Kinematics comes into play – enabling highly precise and efficient machining of large aluminum components.

Tesla is a pioneer in this manufacturing technology, but companies such as Toyota, Hyundai, and Volvo are also increasingly adopting Gigacasting to produce lighter vehicle structures. This advantage is particularly crucial in electric mobility, as reducing vehicle weight helps increase range.

The Challenge: Precise Post-Processing of Gigacasting Components

While Gigacasting offers numerous advantages, the machining of these large aluminum parts presents a challenge. Components such as the underbody or front and rear frames of a car must be processed with the highest precision and efficiency to ensure perfect fit and functionality.

Our PKM – The Perfect Solution for Gigacasting Components

Our Parallel Kinematics Module (PKM) has been specifically developed for machining large components and offers key advantages:

1. Maximum Flexibility:
   – Adaptable to various component sizes and shapes without extensive retooling
   – Ideal for different Gigacasting components, from structural elements to body parts
2. Inline Manufacturing:
   – Seamlessly integrates into existing production lines for maximum efficiency
   – Continuous processing without additional transport routes and changeover times
3. Speed & Precision:
   – Feed rate of up to 50 m/min for ultra-fast machining
   – Maximum contour accuracy for precisely fitting components
4. Optimal Size for Large Parts:
   – Designed for machining large-scale structures
   – Perfect for Gigacasting components
   – High dynamics enabled by strong acceleration and parallel kinematics

Gigacasting & Parallel Kinematics: Efficient Processing with our PKM

With our PKM, we provide a powerful solution for the precise and rapid post-processing of Gigacasting parts. Gigacasting is the future of the automotive industry, and manufacturers need to adapt to the large casting presses that require significant space in production. Our PKM is highly flexible, easily integrates into existing workflows, and ensures precise machining.

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PKM: Applicable in Various Fields

Our Parallel Kinematics Module is a modular system that can be equipped with a wide range of end effectors. Compared to serial robots, it offers 10 to 15 times higher stiffness and accuracy at the end effector. Its innovative mechanical structure allows for geometric variations of the base frame, adapting the working area as needed. The PKM distributes loads onto the building foundation, providing maximum installation flexibility without requiring additional foundations. Moreover, our PKM is highly versatile in hybrid manufacturing across different processes.