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Automotive + Die Casting Industry & Humanoid Robots
The global automotive industry is accelerating the deployment of humanoid robots in factories, shifting from pilot tests to trials in real production lines. Major players like BMW, Toyota, and Xiaomi have announced integrations for tasks such as precision assembly, high-voltage battery work, and die-casting post processes.
On March 2, 2026, Xiaomi announced via its official Weibo that its humanoid robot completed three consecutive hours of autonomous operation at a self-tapping nut installation station in its EV Gigacasting workshop.
Equipped with a five-fingered dexterous hand, the robot achieved over 90% success while meeting the production line's 76-second cycle time. These are initial tests and I’m sure this is not an acceptable success rate for a relatively simple automated task.
It picks nuts from an automatic feeder, places them in positioning fixtures, and coordinates with conveyors for automated tightening on the rear Gigacasting of the Xiaomi vehicles. Xiaomi notes that precise alignment and reliable engagement remain key technical challenges.
BMW has launched a European pilot at its Leipzig plant, deploying "Physical AI" humanoid robots for high-voltage battery and component assembly. This builds on earlier U.S. trials at Spartanburg and underscores BMW's commitment to exploring humanoid potential in mass production.
Toyota, meanwhile, has moved to commercial deployment of Agility Robotics' Digit at its Woodstock plant in Ontario, Canada. A key site for RAV4 production. Following a successful pilot, Digit now supports employees in logistics and manufacturing under a flexible Robots-as-a-Service (RaaS) model, rather than outright purchase.
Though humanoid robots excel in demos for movement and interaction, commercialization remains challenging, particularly in reliably replacing human labor.
Industrial manufacturing, focused on clear needs like sorting, assembly, and handling, offers the most practical path to scale and stands as the primary breakthrough area for humanoid industrialization noted YZWeekly.com.
Morgan Stanley forecasts the global humanoid robot market reaching $5 trillion by 2050, highlighting its immense long-term potential.
Why is a newsletter focused on Gigacastings and magnesium Thixomolding suddenly talking about humanoid robots?
Simple: I'm no AI expert, I honestly have no idea whether the software will ever get good enough to make truly capable humanoid robots a widespread reality.
But on one point I'm completely confident: if that software breakthrough happens, it means multi-billion $ opportunity for the die-casting industry in North America and Europe.
We're talking lightweight, high-precision structural parts in aluminum and magnesium, perfect for agile, affordable mass manufactured robots.
I want you positioned to capture as much of that upside as possible.
P.S. Decision-makers across the supply chains of humanoid robot startups and companies are already subscribed here.
CITIC Dicastal - Leapmotor
CITIC Dicastal's Gigacasting facility in Jinhua, China, has reached a pivotal stage, with final construction of the factory building underway and initial equipment trials in progress. The project team is fully committed to achieving mass production as soon as possible.
The first phase, currently in commissioning, features a fully automated die-casting production line centered on Yizumi's 10,000 ton die casting machine.
Equipped with a two-cavity mold, this line is designed to produce 300,000 front underbody (FUB) longitudinal beam sections annually. Each machined FUB casting weighs 34.3 kg.
Following the completion of Phase 1, Phase 2 will introduce a 7,500-ton die-casting line capable of manufacturing 120,000 rear underbody gigacastings per year at full capacity, with each machined part weighing 50 kg.
Once both phases are fully commissioned, the plant will deliver a total annual production capacity of 450,000 integrated die-cast aluminum alloy components. Leapmotor will serve as the primary initial customer.
The project represents a 300 million Yuan (~$41.9 million) investment. It spans 44,000 square meters of land, with a total construction area of 35,757 square meters.
Leapmotor’s casting does not integrate the shock towers, crash cans, or large wheel arches. Instead, it adopts a simpler, more streamlined solution that is easier to integrate in the body design.
Although this solution may be lighter and twice as many parts can be made with one machine, it offers fewer part reductions and lower cost savings compared to a fully integrated front underbody casting.
Below are examples of similar designs, including Wencan’s solution for AITO and Changan’s for its Nevo brand.
AITO M9 FUB
Nevo E07 FUB
Duoli started production of Leapmotor’s RUB, check out the article here
Volvo Cars selling a complete, unused LK 3,500-ton die casting island
A turnkey production cell: LK Impress Plus DCC 3500, two-platen machine, 35,000 kN clamping force. 2022 build.
The line includes a Støtek two-chamber gas-fired shaft melting furnace, holding furnace with molten metal treatment, and dosing furnace. Two ABB robots handle the cell - one for die spray, one for machine unload, trim press loading, cooling station, and laser marking.
Fondarex Highvac Premium vacuum system. Wollin spray system. Keyence laser marking. LK WB-100 trim press at 1,000 kN. Oil and water temperature control units. KMA Ultravent fume extraction. Outfeed conveyor with cooling tunnel.
Installed and commissioned with dry test run only. Never used in production. Spare parts included.
Located at Volvo's facility in Gothenburg, Sweden.
Jiangsu Mingmei Installed and Ordered More Magnesium Thixomolding Machines
Jiangsu Mingmei Magnesium held the grand opening ceremony for its new magnesium components factory in Jiangsu, China, on March 2, 2026.
The facility broke ground on February 18, 2025, and achieved rapid completion, entering full operation by October 30 of the same year.
In its initial production phase, the factory was equipped with advanced semi-solid magnesium alloy injection molding machines, including 850 ton and 1,650 ton models supplied by Bole Intelligent Machinery.
Mingmei Magnesium aims to become a succesful supplier in diverse high-growth sectors, such as electric bicycles, new energy vehicles (NEVs), aerospace, consumer electronics, medical devices, and beyond.
To support ambitious expansion, Mingmei Magnesium initiated its second round of major equipment procurement at the beginning of 2026, ordering an additional 14 Thixomolding machines. Once fully installed, the company's total fleet will reach 24 units.
The first batch of five machines from this order has already arrived on site and is undergoing commissioning, with the remaining units scheduled to follow in phases.
Delivery of additional 850 ton machines at the factory
Chongqing Magnesium Installed New Die Casting and Thixomolding Equipment
Chongqing Magnesium Technology has successfully completed joint trial production on its new 1,600 ton fully automated die-casting unit island.
In parallel, the company is advancing magnesium Thixomolding technology. Its first 850 ton Thixomolding machine has arrived on site, with installation and commissioning underway.
In 2026, the company plans to advance construction of its new factory, including additional fully automated die-casting islands in the 2,500t to 5,000t range to expand capacity for larger components.
As these upgrades roll out, the product range will broaden from traditional small-to-medium parts to key structural elements such as dashboard brackets, center console brackets, seat frames, and electric drive housings.
Once complete, the new facilities are projected to add 4,000 tons of annual production capacity for magnesium alloy components.
1,600t die casting island
850t Thixomolding machine
