BYD's new cast aluminum frame is lighter and tougher than existing steel frames

EV manufacturers across the globe are constantly looking to decrease the weight of electric vehicles without sacrificing safety. This is crucial for improving the range and speed of modern EVs, so BYD came up with a new aluminum cast that is lighter and tougher compared to similar steel frames.

The new aluminum frame underpins the Yangwang U8L full-sized SUV, and it recently passed a brutal 12-ton lift test and BYD even threw a two-ton tree on top of it. The frame is also approximately 123 lb lighter than a comparable steel frame, which is a standard in the industry.

BYD partnered with the Chinese company Hangte, which develops parts for the aerospace industry. The two companies settled on aerospace-grade 6-series and 7-series aluminum alloy, and that's the first such frame in the automotive industry.

But that's not the unique part. The low-pressure casting process is what makes this frame special. The casting process pushes the metal upward into the mold, which minimizes the voids, creates less turbulence, and results in a denser structure. This way, the frame incorporates 199 parts instead of 251 components. The rear frame alone dropped 67 parts in favor of a single piece.

This new die casting process seems to outperform even Tesla's Giga Press casting, which the Italian Idra Group developed.

Via