On October 13th, inside the Dongfeng Motor’s giga die-casting factory located in the Wuhan Economic and Technological Development Zone, a 16,000-ton die-casting machine intermingled with the sounds of equipment alerts. More than ten engineers, dressed in work uniforms, were conducting pre-production trials and adjustments beside the massive equipment.

A pot of molten aluminum is injected into a mold, which is then sealed and subjected to high pressure before being cooled. Within just two minutes, a complete new energy battery pack tray is formed. This facility, housing the world's largest-tonnage giga die-casting technology, has officially entered the final countdown to full-scale production. The jointly constructed and fully commissioned plant spans 47,000 square meters and houses two installed "industrial giants": integrated die-casting machines with clamping forces of 16,000 tons and 10,000 tons, respectively. Notably, the 16,000-ton machine represents the largest die-casting machine by tonnage globally. Its operating principle involves the moving die applying a force of 16,000 tons against the stationary die, equivalent to exerting the weight of over 200,000 adults across the mold surface.

This represents a transformative advancement in manufacturing technology, remarked Wu Xiaofei, General Manager of the Wuhan Branch at Dongfeng Electronic Technology Co., Ltd., gesturing toward the operational die-casting machine. Traditionally, automotive bodies are assembled by welding hundreds of individual components, resulting in an extended production cycle, a high number of weld joints, and compromised structural rigidity. In contrast, giga die-casting technology enables the consolidation of chassis structural components into three major castings, substantially reducing both part count and weld points, thereby significantly improving production efficiency. Furthermore, this approach not only reduces vehicle weight but also enhances torsional rigidity by 10 to 20 percent.

Precision control serves as a critical indicator of technological advancement. Under a pressure of 40 MPa, molten aluminum is rapidly injected into a 4-square-meter mold cavity and securely clamped using a 16,000-ton locking force, followed by rapid cooling and solidification. The entire production line features a highly automated design, enabling a target cycle time of 135 seconds per unit and achieving a product qualification rate of 95%. "More importantly, our material utilization rate reaches 96%, with full recyclability," stated Wu Xiaofei. "This not only significantly reduces manufacturing costs but also embodies the principles of green manufacturing at the source." The Dongfeng integrated die-casting project is scheduled to commence construction in November 2024, with the main facility expected to complete final inspection by August 2025 as planned. The first phase of the project will involve an investment of approximately 500 million yuan and is projected to achieve an annual output of 200,000 automotive lightweight components. The second phase includes plans to establish four additional production lines, aiming to expand the total annual production capacity to 600,000 units. These lines will focus on producing large-scale structural components for new energy vehicles, including rear floor assemblies and battery enclosures.

Upon reviewing the industry's development, in 2020 Tesla pioneered the use of a 6,000-ton integrated die-casting machine, achieving a 30% reduction in manufacturing costs and cutting the production cycle by over half. Dongfeng Motor has now elevated the tonnage capacity to 16,000 tons, establishing the world's largest die-casting facility. This milestone signifies a critical transition for China, from catching up to assuming a leading position, in high-value-added segments of automotive manufacturing. According to Wu Xiaofei, as commissioning nears completion, the facility is poised for full-scale operation. Marking a shift from technology adoption to independent innovation, and from component assembly to monolithic molding, this factory will serve as a new technical paradigm and strategic blueprint for China’s new energy vehicle manufacturing sector.