Megacasting the future of EVs – GAME on

Tesla’s megacasting, a modular method of car manufacture, could significantly reduce the cost of new EVs. Rival electric carmakers are now looking to adopt this cost-effective production technique.

Tesla calls the process ‘Global Automotive Modular Evolution’ (GAME) or the ‘Unboxing Process’. Giant castings are used to create modules from which the car is then assembled.

An expert in the field said that the process has much fewer production steps than the monocoque process saving cost. He said when other manufacturers follow suit, it will lead to reduced consumer pricing of EVs.

Some other manufacturers like Volvo have already started down the megacasting path, and will be able to compete better in the future with Tesla. But as to when exactly is unclear. 

The ‘monocoque’ construction process kicked off in the 1930s. However, it doesn’t work as well for modern EVs and is expensive compared with the GAME process. Tesla first used this new technique in its model Y SUV.

The unboxing process means vehicles can be made in modules, consisting of front, rear, battery and floor sections. Once these are all assembled, the sides and roof are added to finish the car.

All this could come together when Tesla eventually announces its Model 2 small electric SUV.

The use of ‘gigacasting’ removes the need for over 100 stamping and welding steps in the production process, reducing both weight and cost of each vehicle. 

Industry experts suggest Tesla’s GAME process can slash the cost of manufacturing and will soon be copied by its rivals. 

Given the slowdown in EV demand because of their cost, any initiative that makes them more affordable will be welcomed. Price parity with ICE vehicles is increasingly likely as government regulations make it harder for traditional car makers to meet emissions standards.

Tesla reckons the ‘gigacasting’ modular approach reduces its factory carbon footprint by over 40 per cent while halving total production costs. The company believes its Model 2 will be no more expensive than rival ICE vehicles. 

In the UK this price parity plus ZEV regulations could reignite sales of EVs and Tesla is set to reap the benefits with its upcoming Model 2.