Geely’s EV brand Zeekr is the latest to use Tesla’s “gigapress” die-casting method to lower electric car prices.

Zeekr’s production technology head Jiang Kehong told Reuters that the Chinese manufacturer was employing big aluminum die castings to produce a large rear underbody part of its Zeekr 009 six-seat MPV.

He claimed the technology-enabled Zeekr to reduce over 800 welding places, cut flaws, lighten the car, and stiffen its structure, enhancing the ride of the MPV sold in China this year.

Jiang said Zeekr would employ giga-casting on additional models.

Zeekr’s gigapress approach comes as Chinese rival Xpeng adopts a new vehicle platform technology replicating Tesla’s electric car design and manufacturing.

Metal and plastic die casting has long been utilized in manufacturing, but its usage in carmaking for big aluminum underbodies is new.

IDRA’s newest and largest press clamps are over 9,000 tons. It may knock out the front and rear underbodies that support the car’s skin and suspension components.

Large under-floor battery packs join the front and rear pieces to form a three-piece EV chassis.

Riccardo Ferrario, general manager of IDRA in Brescia, near Milan, says Tesla’s “gigapresses” have simplified manufacturing and lowered costs by up to 40%.

General Motors (GM.N) also employs big die casting to construct the Cadillac Celestiq electrified sedan.

Reuters reported that Toyota (7203.T) is investigating using giga-casting to create EVs.

Last year, Zeekr’s parent Geely’s Volvo Cars (VOLCARb.ST) proposed investing in new EV production technology, including “mega-casting,” at its Torslanda assembly facility.

Zeekr’s Jiang says the carmaker began investigating the technology in 2020 and obtains its large presses from LK, the Chinese business that purchased IDRA in 2008.

Zeekr’s 7,200-ton presses help hammer out the 009’s 1.4-m-long, 1.6-m-wide underbody.

Vehicle repairability is a giga-casting risk. Even a low-speed fender-bender or rear-end impact might make body portions tougher to repair if cast into single pieces.

Most automobiles need bumpers or fenders. However, a giga-cast vehicle may need a complete front or rear piece replacement.

GM is considering smaller-scale giga-castings due to such issues.

“Mega precision sand casting” technology, used to construct the Cadillac Celestiq’s underbody chassis, offers cost and design flexibility in low-volume applications, GM officials stated.

The GM car’s bottom structure comprises six huge castings, including front and rear structures coupled to two 8-foot (2.5-meter) castings adhesively bonded and spot-welded into a floor pan.

“While we are preparing a complete service plan for the Celestiq, at this point we plan to continue to be able to repair castings using our current proven repair procedures used on the Corvette,” a GM representative stated, referring to another large-casting GM automobile.

Toyota is also considering “small portions” giga-casting technology, which separates car bodywork into smaller castings, a source added.

The insider said the plan addresses car repairability problems and Toyota’s global vehicle lineup.

Zeekr can replace pieces of the bigger die-cast section after a collision to address the repairability issue.

The Zeekr CEO claimed that should lower accident repair costs. “We believe customers should not pay extra for our technology innovation.”