The 2024 Giga Press Update Is Here!

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the Giga press is a machine that is
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changing the automotive industry forever
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Tesla was the first company that
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leveraged gigascale diecasting to hack
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the manufacturing process and this has
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allowed them to not only build more cars
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for less money but it’s also enabled
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radical new vehicle designs that we’ve
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only just begun to realize the
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competition is catching on though the
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Giga press is about to go mainstream and
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Tesla will have to push the technology
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further than ever before to maintain
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their lead the stakes are higher than
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ever for the Giga press in
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2024 in a recent interview with Monroe
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live Tesla Engineers revealed something
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very important about how the company
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uses their Giga press machines Lars
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moravi is the vice president of vehicle
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engineering at Tesla he’s been with the
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company for over 13 years so you’re
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looking at one of the most knowledgeable
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people on the planet when it comes to
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building electric cars and Lars pointed
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out a secret behind the Giga casting
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that even Tesla’s competition hasn’t
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realized yet it’s all about the flow if
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we look at this cybertruck front casting
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the first thing you’ll notice is that it
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is really big but more specifically we
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want to take a look at these long
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sweeping metal ridges what does that
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pattern and shape remind you of this is
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a river Delta a naturally occurring
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geological pattern that is created by
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flowing water this same pattern is
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repeated all over the world this is what
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it looks like when water follows the
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path of least resistance and now back to
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our cybertruck casting this is what it
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looks like when flowing liquid metal is
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given the most efficient path to move
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through a diec casting mold what Lars
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points out is that if you put a trained
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engineer alone in a room and have them
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design an automotive casting they are
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going to create a lot of triangles and
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trusses and mathematically correct
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shapes and in theory that design will
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render a very strong and sound component
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but in the actual practice of diec
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casting those rigid shapes create
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bottlenecks that prevent the liquid
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metal from achieving the most optimized
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flow through the mold this is why Tesla
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uses first principles thinking you have
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to throw out everything that you know
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about automotive design and approach
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this problem from the ground up if we
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are trying to cast a very large
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component very quickly using liquid
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metal then we need to create the most
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optimal path for that liquid to follow
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the answer is not in an engineering
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textbook the answer is in nature it’s
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the River delta Lars says that this
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level of innovation is only possible
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because Tesla designs and manufactures
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their own D molds in house so the
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company literally has the people who
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design the castings working in the same
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room as the people designing the molds
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and the two teams can work together to
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ensure that the entire Giga cast system
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is working at maximum efficiency this
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new design approach is what finally made
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the cybertruck possible and it’s going
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to allow Tesla to continue making larger
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and more complex castings than any other
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company would even dream to be possible
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something that we are constantly
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striving for with this channel is
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education my number one goal has always
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been to help you learn something new
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about the technology that is changing
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our world you don’t have to be an expert
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to watch the Tesla B I’m certainly not
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an expert myself and I’m learning right
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along with you so I’m constantly in
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search of free and easy methods to learn
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more about how Science and Technology
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affect the world around us and shape our
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future and the best way for me
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personally to learn new things is by
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doing Hands-On activities this is why
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annual premium
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subscription over the past 3 years Tesla
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has gradually been scaling up the
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capabilities of their Giga press
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machines in simple terms a giga press is
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just a really big injection molding
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device you start with a hot liquid
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material which in this case is molten
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aluminum and then a plunger is used to
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push that material into a hollow mold
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this is your dieye the process of
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forcing viscous liquid metal into a
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restrictive mold is going to create a
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lot of internal pressure and this
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requires tremendous clamping Force to
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hold the two halves of the die together
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as it fills with metal the further the
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liquid metal has to travel through the
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mold the more clamping force is required
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to hold everything together this all
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happens within a fraction of a second
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the speed allows molten aluminum to fill
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every void in the die before the cooling
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process can begin with the casting
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process completed the material is given
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a few seconds to solidify before the
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clamps pull open the die and the
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finished part is removed when when Tesla
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first started Giga casting they were
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able to forge the entire rearend frame
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of a model y using a casting machine
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with 6,000 tons of clamping Force the
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biggest and strongest casting machine in
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the world at the time the first Giga
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press this change alone was able to
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replace hundreds of factory robots and
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individual components with one machine
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making one part with practice Tesla was
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then able to cast the even larger front
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frame section of the model y using the
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same machine and with even more practice
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Tesla has gone bigger once again with
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the cybertruck front end this is still
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done using the same 6,000 tonon press
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from the model y this is proof that
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there’s more to the Giga casting process
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than just raw power you also need design
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efficiency work smarter not harder for
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this gigantic rear casting that supports
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the bed of the cybertruck Tesla did
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eventually need more power this came in
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the form of of an upgraded 9,000 T gig
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press machine even with fluid dynamics
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on your side trying to flow metal across
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this grade of a distance is going to
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require a lot of power to accomplish the
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Cyber truck has been another powerful
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learning experience for Tesla the fluid
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dynamics lesson that we talked about
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earlier being just one example of that
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and all signs are pointing towards
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another upgrade to the gigac casting
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process still to come the Giga press
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version
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2.0 Tesla is currently in the process of
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Designing a brand new vehicle in many
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ways this will be their most
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revolutionary platform to date but at
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the same time it will be the cheapest
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car they have ever sold so how does that
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work well we know that the Next
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Generation vehicle is being built around
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a manufacturing process so in the past
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Tesla would design a car like the model
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3 and then they would figure out how to
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build it this did not work out so well
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the next gen approach is to design a
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manufacturing process that can produce a
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vehicle for half the cost of a model 3
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and do it in half the time and then let
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the end product be determined by the
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most efficient path through that new
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production line one approach that Tesla
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is said to be considering here is a full
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body casting process so in this method
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the entire frame of the vehicle from
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front to back would be forged by one
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Mighty Giga press machine supposedly
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requiring up to 16,000 tons of clamping
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Force to hold it all together under the
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extreme pressure in practice this would
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replace a small army of robot arms
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stamping and casting machines with one
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monolithic Giga press this is getting
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closer to Elon musk’s Mantra of the
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machine that builds the machine this is
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a patent application that Tesla filed
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back in 2018 it’s elon’s concept for a
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singular car building machine titled
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multi-directional unibody casting
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machine for a vehicle frame and
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Associated methods the basic idea a here
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is that raw materials go in and a full
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vehicle frame comes out obviously the
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drawing is an oversimplification you’re
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not going to get wheels and tires and
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windows from a casting machine but this
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is the essence of the Giga press 2.0 the
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concept is not so different from how
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Apple makes their laptops if you’ve ever
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held a MacBook Pro you know that it
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doesn’t feel like any other laptop on
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the market even blindfolded you would
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know instantly that you’re holding an
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app Apple computer and that’s because
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the company manufactures every MacBook
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frame from a single slab of aluminum
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this actually saves the company on
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assembly cost and makes a superior
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quality product running entirely
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contrary to the idea of Full Body
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Casting is Tesla’s unboxed manufacturing
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process this information comes directly
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from Tesla themselves and it distinctly
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shows the vehicle being broken up into
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three main chunks the front and rear
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cast castings plus the structural
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battery pack this also looks like a very
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efficient way to build cars so which one
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is the real manufacturing process for
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the Next Generation Tesla well the unbox
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presentation was a while back in March
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20123 at Tesla’s investor day which was
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one of the company’s less successful
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events it was informative but not very
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exciting it presented some cool ideas
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but gave no specific details it wasn’t
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particularly well received by investors
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so it’s possible that the unbox process
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was just one of many ideas that Tesla
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had in mind at the beginning of 2023
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obviously you’re not going to put all
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your cards on the table in a public
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presentation and we know that plans are
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still changing for the manufacturing of
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the next gen vehicle first it was going
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to be built in Mexico now it’s being
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built in Texas in an interview at the
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cybertruck launch event Elon Musk said
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that he is still reviewing new ideas for
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the Next Generation production process
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on a daily basis it’s also entirely
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possible that Tesla still didn’t believe
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Full Body Casting was possible until
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they had mastered the cybertruck Giga
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cast which could have come after the
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unboxed concept was pitched what we do
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know for sure is that Tesla is still
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very securely leading the way in
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automotive diec casting but the
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competition is beginning to make their
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move or is it of all the major
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International Brands we’ve seen Toyota
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make the biggest move towards giga
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casting but they still don’t have much
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to show for it in June 2023 Toyota
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released this video to Showcase what
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they call their own Giga casting and it
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kind of looks like a Tesla casting but
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at the same time it’s not even close
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here are the new Toyota front and rear
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castings and here are the equivalent
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Tesla Model y castings the Toyota
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components are obviously a bit smaller
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but they also seem to lack all of the
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structure that Tesla has built into
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their casting the Toyota parts look
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thinner they’re much smoother they look
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flimsy in my opinion with that being
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said Toyota does have a decades long
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reputation for making some of the most
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reliable cars in the world so I’m not
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going to sit here and throw any more
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shade at them we will just have to see
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what they eventually come up with the
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First gigac cast Toyota vehicle is
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supposed to be out in 2026 so that’s
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plenty of time we’ve also seen reports
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that Hyundai and Ford have reportedly
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been testing out their own Giga press
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machine Mach made by the same company
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who supplied Tesla the Italian idra
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group idra has reportedly signed a
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contract that would deliver two of their
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largest 9,000 ton Giga press machines to
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Volvo for a new manufacturing plant in
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Eastern Europe Volkswagen is also known
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to be using a smaller 4,000 ton press
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for underbody sections of their new
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Trinity EV platform that will be coming
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in
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2026 this is just more proof that Tesla
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is easily maintaining their position as
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the leader and disruptor of the
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automotive industry there is so much
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more to come

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