Manufacturers worldwide are continually striving to reduce the weight of electric vehicles without compromising safety. This reduction is vital for enhancing both the range and speed of modern electric vehicles. In response, BYD has developed a new cast aluminum frame that is both lighter and more durable than traditional steel frames.
The innovative aluminum frame supports the Yangwang U8L, a full-sized SUV, and has successfully undergone rigorous testing including a 12-ton lift test and even withstanding the weight of a two-ton tree placed on it. Remarkably, this new frame is approximately 56 kg lighter than a comparable steel frame, which is a standard in the automotive industry.
BYD has collaborated with Hangte, a Chinese firm that specializes in parts for the aerospace sector. Together, they have utilized aerospace-grade 6-series and 7-series aluminum alloys, marking a first in the automotive industry.
What sets this frame apart is its unique low-pressure casting process. This method pushes the metal upward into the mold, minimizing voids and turbulence, which results in a denser and stronger structure. The frame comprises just 199 parts instead of 251, significantly simplifying the design. In fact, the rear frame alone has reduced from numerous components to a single piece.
This advanced die casting technique appears to outperform even Tesla's Giga Press casting, developed by the Italian Idra Group.
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