How Ultra-Large Die Casting Machine Supports Lightweight EV Manufacturing

Lightweighting has become a priority across the electric vehicle (EV) industry. Automakers are under growing pressure to reduce vehicle weight to improve energy efficiency, extend battery range, and meet sustainability targets.

To meet these demands, automotive manufacturers—especially in the EV sector—as well as aerospace, rail transit, and heavy machinery industries are turning to large aluminum structural parts, produced in a single piece using ultra-large die casting machines. These components not only reduce the number of welding and assembly steps but also significantly improve structural integrity, production efficiency, and design flexibility.

This shift in production methods isn’t just about size—it’s about rethinking how EVs are made. And corporations like YIZUMI, among the leading die casting machine manufacturers, are leading that change with scalable solutions designed specifically for the next generation of electric mobility.

Why EV Lightweighting Matters

In traditional automotive design, a vehicle might consist of thousands of welded and bolted components. While reliable, these designs add weight and complexity. In contrast, casting large single components—such as entire rear or front underbodies—significantly reduces part count, improves structural integrity, and enhances overall efficiency.

A reduction in vehicle weight translates to improved battery performance, longer range, and ultimately lower production and energy costs per unit. That’s why lightweight materials and advanced production methods have become essential for competitive EV manufacturing.

YIZUMI Ultra-Large Die Casting Solutions

The Role of Ultra-Large Die Casting in Modern EV Production

Ultra-large die casting machines play a key role in helping EV automakers and automotive manufacturers shift from multi-part assemblies to single-piece castings. By consolidating dozens or even hundreds of parts into one, these machines streamline the entire production chain.

Die casting machines in the 6000 to 9000-ton range are capable of forming entire structural parts in one shot. Ultra-large die casting machines must maintain high precision and repeatability to ensure consistent part quality across thousands of cycles.

This evolution goes beyond sheer size. It requires smarter, more efficient, and highly automated systems to handle the complexity and speed of modern EV production—something that’s quickly becoming standard among the most advanced automated die casting setups today.

Key Advantages of Ultra-Large Die Casting in EV Manufacturing

1. Structural Integration Reduces Assembly and Welding

Large body components like rear underbody castings used in EVs would traditionally require upwards of 70 separate parts. Ultra-large die casting machines allow OEMs to produce these as a single unit, reducing welding, inspection, and logistics requirements.

2. Faster Production Cycles

By integrating multiple parts into one casting, manufacturers can drastically cut down on cycle times and labor needs. This leaner production method supports just-in-time manufacturing and improves overall throughput.

3. Higher Material Efficiency

Aluminum alloys used in large-scale die casting are not only lightweight but recyclable, helping EV makers align with global sustainability goals. The reduced scrap and rework rate also contributes to better material usage.

4. Enhanced Structural Strength

One-piece castings minimize weak points caused by joints and welds, leading to stronger, more durable components. This helps automakers meet the structural requirements of safety regulations without compromising on weight.

YIZUMI Ultra-Large Die Casting Machine On-Site Assembly

YIZUMI: A Leader Among Die Casting Machine Manufacturers

For manufacturers looking to scale EV production while maintaining quality and efficiency, YIZUMI offers one of the most advanced ultra-large die casting solutions on the market today.

The LEAP Series ultra-large die casting machine, developed by YIZUMI, integrates global engineering innovation with a deep understanding of industry needs. Designed specifically for new energy vehicles, transportation, aerospace, and more, the LEAP Series is built to support high-performance, sustainable manufacturing at scale.

YIZUMI LEAP Series Ultra-Large Die Casting Machine

Scalable Tonnage Range for EV Megacasting

This ultra-large die casting machine offers locking forces from 6000T to 9000T, making it ideal for large structural components in EVs. This tonnage flexibility allows manufacturers to scale production according to their design needs—whether it’s a rear underbody, battery tray, or front casting.

High Efficiency and Repeatability

YIZUMI’s Yi-Cast self-learning control system ensures accurate casting with consistent results. The real-time closed-loop monitoring adjusts every injection process on the fly, reducing deviations and ensuring part quality.

Compared to conventional machines, the LEAP Series ultra-large die casting machine delivers 10% faster cycle times and significantly enhances die life through reduced flashing.

Automated Die Casting Control with ORCA HMI

The intuitive ORCA-HMI allows operators to manage every aspect of the casting process using an easy-to-understand interface. From setting injection parameters to accessing real-time diagnostics, ORCA simplifies operations while reducing human error.

Built-in features like CastMaster provide process guidance based on expert-level insights, enabling faster setup and smarter troubleshooting—key for automated die casting environments.

YIZUMI Ultra-Large Die Casting Machine

Energy-Saving Operation

Efficiency extends beyond just speed. The LEAP Series ultra-large die casting machine uses proven servo motors and a re-engineered hydraulic system to cut energy consumption by up to 40%. This helps manufacturers not only reduce operating costs but also lower their environmental impact.

Enhanced Mechanical Design for Stability and Safety

YIZUMI’s new toggle system offers higher platen rigidity and extended service life. With better die-position control, automatic die height adjustment, and faster opening/closing speeds, the ultra-large die casting machine enables more reliable, repeatable, and safe operation.

All energy lines and moving parts are enclosed to maximize operator safety without compromising machine access.

Real-World Impact for EV and Mobility Projects

The adoption of ultra-large die casting machines is already transforming how EV platforms are designed. Companies utilizing the LEAP Series ultra-large die casting machine report:

• - Reduced assembly costs and labor by consolidating parts
• - Increased product throughput with shorter cycle times
• - Higher structural performance and quality in casted EV components
• - Greater sustainability through lower material waste and energy use

In high-volume EV production, where every second counts and every gram matters, these improvements make a measurable difference. Manufacturers looking for a dependable and scalable solution are now seeking out advanced, automated systems like those offered by YIZUMI.

Conclusion: A Smarter Path to Lightweight EV Manufacturing

Electric vehicle manufacturers need more than just larger machines—they need smarter, more efficient, and highly reliable solutions that can evolve with the industry. Ultra-large die casting is not just enabling lighter, better EVs—it’s reshaping how they’re built from the ground up.

YIZUMI, as one of the leading die casting machine manufacturers, continues to push innovation in ultra-large die casting machine design. Backed by real-time control, energy-saving technology, and automation-ready systems, the LEAP Series ultra-large die casting machine is helping companies meet today’s demand while preparing for tomorrow’s electric mobility revolution.