Giga Castings with Sandy | Evolution of Tesla Bodies In White

What is the difference to Audi Space Frame?

and when "one part" gets damaged in an accident, then how is "one part" repaired?

"one part" ideology for car body makes repair extremely difficult and expensive. So insurance premium skyrocketed not only for "one part" owners, but for all.

If cars with this kind of manufacturing philosophy replace traditional cars in all price categories, people with low incomes will not be able to repair their cars if there is any significant breakdown. The complexity of manufacturing this kind of parts will make the original manufacturer a monopoly in their production, and the cost will be too high to buy them to repair a used car.

Good for the manufacturer, bad for the owner. Repairability and reusability suffer dramatically.
It also eliminates all aftermarket manufacturers from the scene.

How is the one part casting better other than decreasing complexity of assembly? Every small crash now totals the car - very “well” designed. You’re an engineer goddamit. How can you not see issues like this??

Let's see those cars in a collision test and then we will believe you.

I am an ex casting engineer at a Japanese car company. At my place, casting parts are mostly used in car engines and are under the responsibility of the engine group.

Meanwhile, the body group is responsible for the inside of the car body.

With Tesla's courage and great success in redesigning the car body, there is no doubt that all car manufacturers will follow suit in the next few years.

This could provide benefits to casting engineers wherever they are, as their needs will double or triple in the automotive industry.

Big mistake casting the full front and rear of the vehicles, as can be seen from the 30% increase in insurance costs as a small bump can twist the part and mean the whole back fo the car needs to be disassembled for the rear third of the car to be replaced, seemed like a good idea at the time but needed a bit more thought going into the decision.
Now we can understand why other experienced manufacturers shunned the idea of large castings of the cars.
Sell them for under $20 000, and it might be worth it and insurance costs drop a bit but not that much really. And tesla insurance has been found to be a scam.

Excellent

We tend to think EV when talking about large castings. Do you think any automakers will use them in ICE cars?

Today, on October 29th, 2023… Still… This video shows in one word of how to succeed … EVOLUTION… The old automakers are not evolving… Tesla has evolved EVEN in the “field of expertise” of the legacy automakers … How to efficiently make a Body-In-White… In less than 10 years, Tesla has evolved what the other Automakers have not evolved in 100 years…. Unbelievable… By the way… This is more than a video… It’s an Automotive Engineering Class with Professor Sandy Munro.

Ppl always give Elon too much credit and not enough to his staff that actually make the decisions at tesla.

I am very proud and happy to work in this department at the GFBB in Germany after hearing these words and your comments (Special thanks to the great man for this beautiful (explanation

5 star presentation on Tesla drive to be perfect, each time, every time. Extremely informative, clear, concise and to the point. JWD!

How does the cast handle a car accident?

If the design team of a automaker company is looking for advise on a small consultancy of an old man and not developing their own, be Shure that they are doomed!

Zero repairebility nice😮

I would really like to inspect the quality of the casting without paint. In my experience thin walled extreme castings tend to be rather poor regarding surface and internal quality. Fatigue strength is highly dependent upon proper surface integrity.

I would prefer to be one step behind when taking gigant leaps into areas of new technology - it seldom goes without problems. The speed that Tesla is implementing new technologies could be due to high risk acceptance within the company.

This is interesting and does show a progression of engineering for the sake of manufacturing. But I have huge doubts about this product (car) from the consumer's point of view. If you are in a crash- a side impact at the rear tire- and your casting is broken at several locations. Is this going to be repairable? TIG welding isn't going to put the exterior shape back together. If not then the car would be "totaled". Who is going to bear the burden of vehicle replacements for an expensive EV that is not repairable?

Repairability ??

“That’s contrary to popular belief, I’m not popular.”

Love it Sandy 🤣

Tesla fanboy much?

I worked in an accident repair shop 30years ago. We repaired really heavy accident damage on the expensive models back then, but today it seems to me that we have "moved on" and are just dumping the whole car. I think this path will end in the next few years, and we will learn to repair again and build vehicles that can be repaired. Of course with castings, but none in one piece...

"I'm sure there's some engineers out there going, 'Oh no, he's gonna rub our noses in it again'.
And the answer is correct; let's go over here ..."

Peak Sandy Munro lmao.

Non engineer here but one reason i see the legacy auto being slow to adopt large casting is that the customer wont see an appreciable difference in the appearance of the product. There is most likely a weight penalty with the old system but that could more cheaply be offset with a larger battery module than retooling an assembly line thats already paid for with validated processes in place.

Wonderful video. Thanks for the input Sandy!

Prominent investors are more interested in the cost of quality profit margins. Dealerships also will profit from going out of warranty spare part sales and service. Do you actually believe they could not make a 500,000 car? Have you seen the price of a Gulfstream 6 and a board member American Express card?

Holy shit one part?! What the fuck!

what is the weight comparison between old and new method?

😂sir, I think you just helped Tesla sell one more car, to me

I can see how all of these changes represent significant improvements in the manufacturing process, but do they make the car safer to drive? For that matter, is the new battery safer? Could there be some advantage in previous the body construction in an accident that may allow for more deformity or cushioning that is being lost in this new and improved manufacturing process? In short, would you rather drive with your kids in the backseat of this model Y or the previous one, sitting on top of the new battery or the previous one?

… Why did the animals evolve, you asked. And then you gave the reason saying “…something to do with intelligence“. From the way you’re talking, I have a feeling you don’t know much about biological evolution. I wish you did, you would sound smarter.

Would be good to get some weight and stiffness numbers.

How is the casting’s strength and weight compared to sheet metal?

Sandy Monro for president 2024

The casting process is incredible engineering and very beneficial to cost reductions at Tesla. While you can tig weld new cast sections in the event of a crash, Tesla is unlikely to sell sections of the casting in order to do so. As a result, a crash is more likely to result in a total loss which benefits Tesla because its an opportunity to sell another vehicle. Reparability is important and should not be forgotten because a technology is green. Thanks for the vid

Great video! Do you think other OEMs will move to Giga casting too? If so, what material should benefit from the change? Steel, aluminum, composites? Thank you.

It's a Tesla, gentlemen. I really liked the way the car body industry developed, as it can be manufactured at a lower cost than pressure molds. I think that Tesla is the future in the car body industry, and we hoped to abandon the resistant iron and replace it with aluminum that does not rust

Full vertical integration is going to overtake manufacturing AGAIN!

So how does this change small collision repairs?? Seems like smaller pieces are easier to replace.

Does Elon Musk wear Giga underpants?

Delightful, interesting, educational, and a lot of fun to watch !!! Thanks, Munro & Associates !!!

how am i just now finding this channel ( came from the tesla channel), repairability should not be a qualification for use.

How can Tesla do this? Like the tooling (factory) to make a model 3 change so much in the same generation?

Great! With all that cost savings, then why hasn’t the price been lowered accordingly!