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’s 47,000 m² “world’s largest” integrated gigacasting plant finished 25 days early; to house 16,000-tonne and 10,000-tonne lines with mass production due June 2026
The completion of a 47,000-square-meter die‑casting facility marks a notable step in large‑scale gigacasting for Dongfeng Motor. The plant was finished 25 days ahead of its contract deadline, and it is positioned as the core production base for the company’s broad gigacasting industrialization plan. The project is designed to support mass production in the coming years, with expectations set for June 2026 as the start of full manufacturing activity.
The project team implemented BIM to streamline construction workflows, contributing to the accelerated handover and smoother integration of future production lines. The completed facility will eventually house dual integrated die‑casting lines featuring 16,000‑tonne and 10,000‑tonne gigacasting machines, described as the largest of their kind worldwide. When these lines are fully operational, they are expected to deliver meaningful gains in both output and efficiency for the company’s new energy vehicle (NEV) manufacturing segment.
Construction of the plant began in November 2024, and the building portion was brought to completion in a single phase. The project is structured in two stages, with the initial phase installing one 10,000‑tonne line and one 16,000‑tonne line. The first phase is projected to yield an annual production capacity of about 200,000 components, before additional lines are added in the second phase to reach a total of 600,000 components per year.
The overall investment for the project is around 1 billion yuan. In addition to delivering size and speed, the gigacasting approach aims to strengthen vehicle bodies and improve both safety and efficiency in NEV design by casting larger, more integrated components in fewer steps. The facility’s target components include rear floor assemblies and battery casings, with the production focus centered on research, production, and sales of ultra‑large gigacasting structural parts for NEVs.
The multi‑phase rollout will unfold gradually, with the physical factory completed in a single phase while the casting lines are added over time. Once the two initial lines come online, the plant will start by supporting a significant but partial production capability, expanding to full capacity after completing the second phase. Mass production for the site is slated to begin in June 2026, aligning with the broader push toward gigacasting as a standard method in EV manufacturing.
The project is described as a flagship in the broader shift toward mega‑casting, where a single machine or a small set of machines can form large portions of a vehicle structure. The emphasis on ultra‑large casting capacity and integrated components signals a move away from assembling many small parts via welding toward constructing larger modules in one step. This approach is intended to shrink the number of moving parts, reduce assembly time, and lower labor requirements, while also enabling more efficient use of space within factory floors.
In summary, the Dongfeng facility stands as a high‑profile example of how gigacasting is evolving from a concept to a scalable production strategy. With a large factory footprint, two oversized lines, and a staged path to full output, the project highlights both the technical ambition and the practical planning needed to advance mass production of NEV components through ultra‑large die casting.
FAQ
What is the purpose of the Dongfeng gigacasting plant?
The facility is designed to produce ultra‑large NEV structural components using gigacasting, serving as the core production base for the company’s large‑scale gigacasting program.
What does gigacasting involve?
Gigacasting uses ultra‑large die‑casting machines to form multiple parts into a single structural component under high pressure, reducing parts, welding, and assembly steps while aiming to improve safety and efficiency.
When did construction start and when was completion announced?
Construction began in November 2024, and completion was announced on September 4 of the implied year, 25 days ahead of the contract deadline.
What are the initial production lines and their capacities?
The first phase installs one 10,000‑tonne line and one 16,000‑tonne line, with an initial annual capacity of about 200,000 components.
What is the total planned production capacity after full deployment?
After the second phase, the plant aims to reach a total output of about 600,000 components per year.
What is the expected mass‑production start date?
Mass production is expected to begin in June 2026.
What is the estimated investment for the project?
The project is planned with an investment of around 1 billion yuan.
What technological approaches accompany the project?
Key elements include ultra‑large gigacasting machines, a two‑phase expansion plan, and the use of BIM to support construction and future production efficiency.
What components are targeted for gigacasting?
Targeted components include rear floor assemblies and battery casings, among other large structural parts for NEVs.
| Feature | Details |
|---|---|
| Location / Scope | 47,000 m² gigacasting plant in China as core base for NEV structural components |
| Initial Lines (Phase 1) | One 10,000‑tonne line and one 16,000‑tonne line |
| Total Capacity (Phase 1) | Approximately 200,000 components per year |
| Total Capacity (Phase 2) | About 600,000 components per year |
| Investment | Around 1 billion yuan |
| Timeline | Construction began November 2024; completion announced September 4 (year implied); mass production planned June 2026 |
| Technology | Gigacasting with ultra-large die-casting machines; BIM used in construction and planning |
| Targeted NEV Components | Rear floor assemblies and battery casings |
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
