High Pressure Die Casting

Injection Cycle

Solid metal chunks are melted in a furnace before being injected at high velocity into the die chamber. The sequence of high pressure die casting involves closing the massive steel plates and firing the plunger at thousands of pounds of force. High speed filling prevents the metal from solidifying before the corners of the mold are saturated.

This results in a smooth surface that requires very little extra machining after cooling. Rapid ejection allows the next piece to start almost immediately.

Structural Quality

Aluminum alloys used in this process yield parts that absorb energy effectively during a crash event. Consistent cooling across the mold ensures that no internal air bubbles weaken the finished frame. High pressure die casting results in a dense grain structure that holds screw threads firmly without the need for inserts.

Such integrity is necessary when mounting dozens of battery modules inside a single large tray. Uniformity allows for automated assembly robots to work without needing to adjust for individual part errors.

Scaling Benefits

Initial investment in the custom steel molds represents a major portion of the project budget. High pressure die casting pays off once production reaches several tens of thousands of units per year. It removes the need for dozens of small stamped parts that would otherwise require multiple welding steps.

Fewer joints mean fewer potential leak points for water entry into the pack. Lower complexity in the assembly line saves time and floor space. Reliability of these cast parts anchors the safety targets of modern long range vehicles.

Final verification happens through x-ray scans to check the internal wall consistency.