The pack frame is a significant structure and often made up of many parts welded, bonded and fixed together. One option is to cast the frame in one part. These frames in vehicles can be very large and hence a giga casting, then benefits are:
- one part
- 10% lower weight
- 15% lower part cost
Note: this is based on the VW Polo MEB+ battery frame and we will add to this as we get more data.
2026 VW Polo MEB+
1.7 m long, 1.15 m wide, which replaces 123 individual parts and helps reduce weight by 10%, to 62 kg.
Further details describe a 120 seconds cycle time and the use of 3 plate die technology. The cost reduction is 15%.
Volkswagen Embraces Gigacasting, Industry Arsenal
References
- Volkswagen Embraces Gigacasting, Industry Arsenal
See also: Pack Enclosure Materials, Enclosure Design, Exploring Different Battery Tray Designs, Rivian R1 Gen 2 Battery