China, September 8, 2025
News Summary
Dongfeng has finished construction of a 47,000 m² gigacasting factory 25 days ahead of schedule, allowing earlier equipment installation and commissioning. The single‑phase building will house ultra‑large die‑casting lines including a 16,000‑tonne unit and a 10,000‑tonne unit, positioning the company at the forefront of large‑format casting. Using Building Information Modeling (BIM) sped coordination and delivery. The project targets phased production capacity with an initial annual output goal of 200,000 components and a later scale‑up to 600,000 after additional lines are added. Investment is about 1 billion yuan and lines will be brought online gradually.
Dongfeng completes 47,000 m² gigacasting plant 25 days early; mass production set for June 2026
A new die‑casting factory built for a major automaker has been finished nearly a month ahead of schedule. The completed building covers 47,000 square meters and will become the core production base for the automaker’s large‑scale gigacasting push. The plant was turned over 25 days early, with the construction team crediting digital planning tools for the accelerated handover. The site will house two ultra‑large casting lines, using 16,000‑tonne and 10,000‑tonne machines, and mass production of structural components is expected to begin in June 2026.
Key project facts
Construction began in November 2024. The factory building was completed in a single construction phase and the full project is being developed in two phases. The first phase will see installation of one 10,000‑tonne line and one 16,000‑tonne line, giving the plant an initial annual production capacity of 200,000 components. A second phase will add four more lines, raising total output to 600,000 components per year. The overall project investment is around 1 billion yuan.
Construction methods and schedule
The construction contractor reported use of Building Information Modeling (BIM) to speed coordination and lower error rates during design and build. According to the contractor’s announcement, BIM helped to streamline site layout, prefabrication and installation sequencing, which supported the early handover. The plant building was delivered ahead of the contractual deadline and now will be prepared to receive the casting lines, which will be rolled out gradually rather than all at once.
What will the plant make and why it matters
The factory will research, produce and sell super‑large gigacasting structural components for new energy vehicles (NEVs). Targeted parts include large items such as rear floor assemblies and battery casings. The two planned machines — a 16,000‑tonne press and a 10,000‑tonne press — are described as among the largest available and will be used to cast multiple parts into single, large structural pieces under very high pressure.
How gigacasting works and its production effects
Gigacasting uses ultra‑large presses to force molten aluminum into a die that contains the shape of a large structural piece. After cooling and trimming, a single cast component replaces many smaller stamped and welded parts. This method can reduce the number of parts and welds, cut assembly steps and floor space, and increase unit output and efficiency in high‑volume NEV production. The use of large, integrated castings is intended to strengthen vehicle bodies, improve crash performance, and lower manufacturing cost per unit when volumes are high.
Industry context and tradeoffs
The shift to large‑scale die casting follows broader adoption of integrated casting in the EV sector. Several automakers and suppliers worldwide have explored and deployed large presses to simplify body structures and reduce weight and cost. Benefits touted include fewer welding stations, fewer robots on assembly lines, and faster assembly cycles. Challenges include high upfront equipment cost, new design and validation steps for alloys and mold behavior, and changes to repair and inspection processes that follow from making large one‑piece structures.
Next steps
With the building completed, installation of the casting lines will proceed in stages. The first two lines in phase one will be installed next, enabling the plant to reach its initial annual capacity of 200,000 components. Final ramping and commissioning aim to reach full mass production in June 2026, by which time the plant will supply large structural parts for the automaker’s NEV programs.
Builder and source of the announcement
The completion notice and accompanying image were issued by the construction company responsible for the build. The contractor credited BIM tools and coordinated scheduling for the early handover and said the facility will act as the central production site for the automaker’s gigacasting industrialization plan.
FAQ
What was finished early?
The factory building for an integrated gigacasting plant covering 47,000 square meters was completed 25 days ahead of schedule.
What machines will the plant use?
The plant will house one 16,000‑tonne and one 10,000‑tonne integrated die‑casting line in its first phase. These presses are among the largest currently in use.
When will production start?
Mass production of cast structural components is scheduled to begin in June 2026, after phased installation and commissioning of the casting lines.
What will the plant produce?
The focus is on super‑large structural components for new energy vehicles, such as rear floor assemblies and battery casings.
How much will the plant produce each year?
Phase one capacity is 200,000 components per year. After phase two, total annual output is planned to reach 600,000 components.
Key features at a glance
| Feature | Detail |
|---|---|
| Completed area | 47,000 square meters |
| Early handover | 25 days ahead of contract deadline |
| Key equipment (phase one) | One 16,000‑tonne and one 10,000‑tonne gigacasting line |
| Initial annual capacity | 200,000 components |
| Final planned annual capacity | 600,000 components (after phase two) |
| Investment | About 1 billion yuan |
| Mass production target | June 2026 |
| Construction method | Building Information Modeling (BIM) used for design and coordination |
Deeper Dive: News & Info About This Topic
Additional Resources
- Reuters: Tesla Shanghai plant starts Model Y production with new cost‑cutting methods
- Wikipedia: Gigacasting
- CNEV Post: Tesla Shanghai produces Model Y with integrated die‑casting
- Google Search: Dongfeng gigacasting plant
- CleanTechnica: Let’s go gigacasting
- Google Scholar: gigacasting electric vehicle
- InsideEVs: Tesla reportedly makes one‑piece giga‑casting breakthrough
- Encyclopedia Britannica: die casting
- Gasgoo Auto News: China auto industry (gigacasting project)
- Google News: gigacasting
Author: Construction CA News
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