Volvo is set to revolutionize the production of its next-generation electric cars by incorporating mega-casting into its manufacturing process. This advanced technique involves pouring molten metal into a die-cast mold to create large single car parts. By producing sections of the car platform as single pieces, Volvo can eliminate the need for numerous separate parts and reduce complexity. The first part to be produced using mega-casting will be the rear floor section, which will replace around 100 parts and have 84% fewer welded joints. This will result in a weight reduction of around 50%.
The introduction of mega-casting aligns with Volvo’s plans to launch its third generation of bespoke electric cars on the SPA3 platform. While the company has not revealed details about the first model to be produced on this platform, it is clear that there is a gap in Volvo’s electric lineup for an EX60, which would sit alongside the popular XC60 SUV. The Torslanda plant in Sweden, where the mega-casting process will be implemented, is a natural choice for production due to the EX60’s significance within Volvo’s product portfolio.
One of the advantages of mega-casting is that it offers greater freedom for vehicle design and manufacturing. Mikael Fermér, Volvo’s vehicle platform lead architect, explains that the technique allows for more substantial changes to the structure of a platform. This flexibility is achieved by simply adapting the molds used in the casting process, giving the platform an “unlimited lifespan.” It also enables more rapid deployment of new vehicle types. Fermér highlights that mega-casting is not limited by imagination but should be based on the business case and function.
Safety is a crucial consideration when implementing mega-casting. However, Volvo assures that there are no concerns in this regard. The mega-cast parts are designed with safety in mind, and if they are damaged in a severe crash, they can be replaced. Repairing a mega-cast part is possible to some extent, but it may be scrapped in the case of a severe crash. However, this is no different from traditional cars where the main body can also be written off in severe accidents.
In addition to the design advantages, mega-casting offers significant production benefits. It reduces CO2 emissions by reducing the number of parts that need to be shipped from outside suppliers or other Volvo factories. It also allows for higher material utilization, as any leftover aluminum can be melted down and re-cast. Volvo plans to increase the use of mega-casting in the future, with the goal of producing much of the platform as a handful of pieces.
The introduction of mega-casting at Volvo’s Torslanda plant is part of a major £800 million upgrade to prepare for future electric car production. The company is also constructing a new battery assembly plant and production facility in partnership with Northvolt. The mega-casting technique may eventually be implemented across Volvo’s other global plants as the need arises.
In conclusion, Volvo’s adoption of mega-casting in the production of its next-generation electric cars is a significant step towards improving efficiency and creating more design freedom. This advanced manufacturing process allows for the production of large car parts as single pieces, reducing complexity and weight while increasing safety and design flexibility. As Volvo aims to become fully electric by 2030, the use of mega-casting will play a crucial role in realizing this vision and transforming the way cars are constructed.
