Your company uses megacasting to manufacture vehicles. How long have you been using this technology, for which components and for which models?
Cheng Xu: Millison initiated pre-research on equipment and mold parameters in 2019. In April 2022, a formal trial mold of 8,800 tons was conducted, resulting in a successful first sample delivery. In November 2022, mass production officially commenced, with the mass production of 7,000 tons officially commenced underway in February 2023.
We employ this technology for the production of structural components in E-vehicles, such as the front cabin, rear floor, and battery trays etc. Notable applications include the NIO’s E-vehicle models of ES8 and ET5, as well as structural components for some renowned traditional European automotive companies.
The technology is considered to be demanding in its application. What is your experience with it so far?
Cheng Xu: Indeed, the application of new non-heat treatment material, the design of equipment parameters, mold design and process design for die casting manufacturing is no longer a simple of selection. Instead, it builds around a creative process based on „first principles”. In the absence of experience and standards, many die casting manufacturers and OEM automotive companies have engaged in Megacasting, exposing them to meaningful risks.Although the interim results may vary, each with respective advantages, the different manufactures all encounter significant challenges.
From a business perspective, the first requirement is a sufficient number of orders to support the investment in multiple sets of molds, ensuring optimal equipment utilization, while the qualification rate is also crucial. Meanwhile, to maintain the thermal balance of the molds, high energy consumption is another significant issue that needs to be addressed.
