Integrated Die Casting vs. Traditional Die Casting: A DeepSeek Comparison!

1. Technology Route Comparison

1.1 Fully Integrated Die Casting

• Technical Features: Integrates dozens of traditional components into a single large die-cast part.
• Typical Applications: Rear floor panel, front engine compartment, integrated bottom plate.
• Advantages:

• Reduces weld points by over 90%.
• Improves production cycle time to 2–3 minutes per part.
• Decreases factory footprint by 30%.

1.2 Limited Integration + Connection Technology

• Features: Modular integration of 5–10 components combined with mechanical connections or welding.
• Typical Applications: Chassis structural components for traditional automakers, battery pack enclosures.
• Advantages:

• Tooling development costs reduced by 60–70%.
• Production line modification costs are roughly one-third of that for full integrated die casting.
• Offers greater flexibility in maintenance and replacement.

2. Cost Structure Comparative Analysis

3. Balancing Strategy and Case Studies

3.1 Recommendations for Technical Route Selection

For annual production volumes, the suggested approaches are:

• Less than 50,000 vehicles: Limited Integration + Connection (to control investment risks)
• 50,000 to 150,000 vehicles: A Hybrid Approach (fully integrated for key components)
• More than 150,000 vehicles: Fully Integrated Die Casting (to leverage economies of scale)

3.2 Benchmarking Industry Practices

• Tesla:
• Approach: Fully integrated route (annual capacity > 500,000 units)
• Cost Advantage: 40% reduction in manufacturing cost per vehicle
• Risk: Higher maintenance costs lead to a 20% increase in insurance fees

• Volkswagen Group:
• Approach: Modular integration strategy (e.g., MEB platform battery pack uses five die-cast parts with bolt connections)
• Result: Approximately 25% cost reduction compared to traditional methods, with controllable maintenance expenses

• NIO:
• Approach: Flexible solution
• Result: Overall cost reduction of 30% and a 40% reduction in maintenance costs compared to Tesla

4. Future Trends Forecast

• Technological Convergence: After 2025, an "intelligent hybrid" approach is expected where the main structure is produced via fully integrated die casting, while vulnerable parts adopt a modular design. This will achieve an optimal cost balance with an integration rate of 60–70%.
• Equipment Evolution: Development of modular die-casting units capable of switching between 6,000–12,000T and fast mold-change systems (under 4 hours).
• Material Breakthroughs: Innovations such as self-healing aluminum alloys and low-cost titanium die-casting technologies.

5. Recommendations

For most automotive manufacturers, a phased implementation strategy is advisable:

• Short-term (1–3 years): Implement fully integrated designs for key load-bearing parts alongside modular designs for non-critical components.
• Mid-term (3–5 years): Increase the degree of integration to 50–60%.
• Long-term (5+ years): Choose between full integration and an intelligent hybrid approach based on market scale.

Final decisions should consider product positioning (luxury vs. mass market), annual sales forecasts, after-sales service capabilities, and the depth of technological reserves.