Volvo announced a US$1 billion investment to build a new electric vehicle production line including a battery production line and a giant die-casting machine. Does this innovative process sounds familiar?
Volvo (Geely Volvo) announced that it will invest heavily in the development of new production lines and manufacturing technology in its Swedish factory with an investment of up to 10 billion Swedish kronor (approximately 30 billion Taiwan dollars). Expected to start operation next year, these production lines will build a new generation of pure electric vehicles.
According to an official statement, Volvo hopes to provide customers with cheaper pricing, greater battery life, and faster charging cars, while taking into account sustainability and safety. Thus, they need new manufacturing technology including a new battery assembly plant, a completely rebuilt paint and assembly hub, as well as a special "giant die-casting machine for aluminum chassis components."
This die-casting machine built by Volvo is very similar to Tesla's previous die-casting machine. By forming die-cast parts in one piece, the assembly process is simplified and manufacturing cost is reduced. However, Tesla uses cast parts in the front and rear end, while Volvo only uses a one piece cast rear undercarriage.
The advantages of using all-aluminum unibody components are obvious. It can reduce weight, reduce welding processes, keep overall structural safety unchanged, and greatly reduce the carbon emissions of vehicle manufacturing. Volvo further utilizes body design and new components to manufacture new electric cars with greater interior room and storage compartment space, a move that captures “two birds with one stone.”
In addition to the giant die-casting machine, Volvo is also partnering with battery company Northvolt to develop lithium batteries for new electric vehicles. The two parties have jointly invested in a new battery production line. At the same time, Volvo’s plant is also adapting to the electric vehicle manufacturing process, changing its feeding line and upgrading its paint and final assembly stations to create a more competitive next-generation electric vehicle.
Volvo hopes to transform into an all-electric car company by 2030 and the Torslanda plant in Sweden is a key starting point.
Looking at the shortcomings of integrated die casting, the first problem is that capital invested in equipment is extremely high. For traditional car manufacturers, such a huge process change not only burns money but is also full of uncertainty. The second problem is logistical maintenance. If the one-piece casting is damaged, the whole part is likely to need replacement, unlike a multi-part assembly where only a few parts must be replaced.
In other words, in the short term, the market will only see the advantages of one-piece die-casting but, as logistical issues increase, its disadvantages will gradually be seen. The carmaker’s emphasis between improving efficiency and facilitating maintenance will determine the degree to which castings are used.
（Image：Volvo）