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New Vehicles Entering Production
The Beijing Auto Show 2026, one of the most important events in the global automotive industry, took place from April 24 to May 3.
Among the many cars unveiled in this period of time, some have been present in The Gigacasting Database for quite some time, now they are finally unveiled and some already in mass production.
Xpeng GX
The Xpeng GX, a flagship SUV is the latest addition to the Xpeng lineup, features a front and rear underbody Gigacasting architecture with an integrated structural battery pack at its core.
Sharing the same platform and production facility as the G6, G7, X9 and P7+, the GX also shares its rear underbody Gigacasting with the X9. This strategic overlap optimizes manufacturing efficiency by utilizing an existing Gigacasting design and mold, instead of designing from scratch for a vehicle position in the premium range with low production volumes.
Guangdong Hongtu’s 12,000 ton die casting island, installed within the same facility under the “Factory within a Factory” model, supports rear castings. This integrated approach is widely adopted in Gigacasting production for enhanced efficiency in logistics.
Nio ES9
Another flagship SUV from the Chinese EV startup Nio. The ES9 adopts a rear underbody (RUB) design that follows the same integration philosophy as every other Nio vehicle: relying solely on structural links, avoiding flat areas, and optimizing for weight savings and torsional stiffness.
The front underbody follows the same minimalist approach, incorporating only the so-called “longitudinal lower beam.” Cast wheel arches were deliberately omitted because they added more weight than they delivered in benefits for a premium EV.
Overall, these design choices can be summarized as a deliberate focus on weight optimization—while still achieving a very safe and stiff vehicle—coupled with cost reductions and part-count minimization.
Luxeed V9
Luxeed is part of a series of brands (HIMA) created by joint ventures between Huawei and state run Chinese OEMs. In this case, Luxeed is a brand under a joint venture between Huawei and Chery Auto.
The RUB integrates 78 dispersed parts into one single integrated die-cast component, eliminates 760 weld points, dramatically improving structural integrity, rigidity, assembly precision, and crash performance.
Structural parts weight reduced by 15.5%, contributes to better vehicle efficiency, lower center of gravity, and improved handling.
The Luxeed V9 is the first MPV across all the HIMA brands. It’s not the first vehicle to adopt a rear underbody Gigacasting for Chery, nor for Huawei, more details about it below.
Volvo EX60
The Volvo EX60 is being built today at the Torslanda plant in Gothenburg, and customer deliveries begin in early summer. After nearly three years of reporting on this project - from the machine installation to the first casting images - the EX60 has crossed the only line that matters and it’s now in mass production.
Full resources Volvo EX60: https://www.industryarsenal.com/p/weekly-gigacasting-news-49
Other new vehicles, the Onvo L80, Leapmotor D19 and more included in The Gigacasting Database
Staying ahead in the fast-moving Gigacasting industry is challenging
Especially with most breakthroughs concentrated in China, while Western OEMs remain cautious about adoption
There's a smarter way to stay one step ahead and gain a clear, comprehensive view of the entire market
I’m Luca Greco, the author of The Gigacasting Newsletter and I built The Gigacasting Database precisely to address your specific needs
It tracks Gigacasting machines ordered and installed worldwide, models adopting the technology (with images & descriptions of each casting), production volumes, OEM-supplier relationships and mappings, upcoming vehicles and platforms planning to implement Gigacasting… and much more
20th Shanghai International Diecasting & Nonferrous Exhibition
I will attend the International Diecasting & Nonferrous Exhibition. Held at the Shanghai New International Expo Center (Hall N1–N4) From July 15ᵗʰ to 17ᵗʰ.
Under the theme “Twin Engines: Al & Mg, A Lightweight Future”
This is your biggest chance to learn about Gigacasting and magnesium Thixomolding, meet people and companies, directly where most of the innovation in the die casting industry is taking place.
Book your visit, your booth or a special factory tour here
Is there any company you want to meet privately at the event? Visit diecast-event.com/cid, alternatively you can directly contact;
Ms. Tracy Feng | Tel/WhatsApp: +86 13916927105 | Line: +66 980427102 | Email: [email protected]
Ms. Sunny Song | Tel/WhatsApp: +86 13761250456 | Email: [email protected]
SEA Die Casting 2026
Another event I highly recommend and which I plan to attend in the future, is the South-East Asia Die Casting.
Bangsaen, Chonburi, Thailand – SEA DIECASTING 2026, Southeast Asia’s only dedicated die casting conference and exhibition, will take place from May 20–22, 2026.
Under the theme “Powering Southeast Asia, Forging a New Age”
The event will unite global industry leaders, experts, and key decision-makers to shape the future of die casting in the region.
Southeast Asia has emerged as a key hotspot for international manufacturing investment.
Thailand, in particular, is at the forefront of this transformation, with its rapidly growing electric vehicle and electronics sectors driving strong demand for advanced die casting solutions and integrated supply chains.
Is there any company you want to meet privately at the event? Visit diecast-event.com/cid, alternatively you can directly contact;
Ms. Tracy Feng | Tel/WhatsApp: +86 13916927105 | Line: +66 980427102 | Email: [email protected]
Ms. Sunny Song | Tel/WhatsApp: +86 13761250456 | Email: [email protected]
Do you plan on visiting any of these events? If you do write to [email protected] or any of my social media channels and let me know!
Luxeed V9 And The “Electromagnetic Thermal Control System”
Along with the Luxeed V9, Chery Auto and Huawei presented a new Gigacasting process with an “electromagnetic thermal control system” (电磁热控压铸技术).
This system, although there is not much clarity and transparency around it, is said to move beyond the industry’s “tonnage arms race” and “brute-force” high-pressure, high-speed filling of traditional high-pressure die casting. Instead, it emphasizes precision intelligent control (“巧劲” clever force over 蛮力 brute force) for superior quality.
The following description of how this system works is based on information provided by Luxeed and reports from the Chinese industry press.
Luxeed has not directly confirmed whether the process is a semi-solid rheocasting-like method that uses electromagnetic stirring or a different form of electromagnetic heating.
Notably, the sources never use the term “semi-solid”; they consistently refer to the material as “molten metal.”
The system fuses two core innovations applied to molten aluminum:
1) An electromagnetic field is applied directly to the molten aluminum. It “energizes” the melt, disrupts surface tension, and dramatically improves its rheology/flow behavior.
Turns thick, viscous aluminum into smooth, low-viscosity liquid. This allows slow, stable, highly controllable, and uniform filling of even complex mold cavities without turbulence, splashing, or air entrapment.
Result: minimal defects, complete filling of thin walls/far corners, and “intelligent navigation” of the flow rather than chaotic high-speed injection.
2) Nano Thermal Control Layer + Electromagnetic Induction Heating:
The die/mold surface features a nanotechnology thermal control layer that acts as an intelligent “thermostat” or “heat switch.”
During filling: High insulation — keeps the aluminum at stable high temperature so it does not cool or solidify prematurely. Enables the slow, complete fill described above.
During solidification/cooling: Instant switch to ultra-high thermal conductivity — rapid heat extraction (near-quenching effect, cooling from ~700°C quickly). Promotes fine, dense grain structure for the observed strength gains.
Electromagnetic induction heating: An electronic circuit board generates an alternating magnetic field. The mold surface cuts magnetic lines, inducing eddy currents that heat the mold itself with >95% thermal conversion efficiency. This enables precise, zoned, or staged temperature control across the entire process.
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.
Bole Will Deliver A 7,500 T Magnesium Thixomolding Machine
Bole Intelligent Equipment has signed a purchase agreement and strategic cooperation deal with Shanxi Xuedong Intelligent Technology for the supply of 14 magnesium semi-solid injection molding machines with clamping forces ranging from 300 to 7,500 tons.
The equipment will support Shanxi Xuedong’s expansion into high-end light alloy structural components for aerospace, defense, automotive, and civilian applications. The two companies will also collaborate on process development and technical improvements in light alloy forming.
Shanxi Xuedong, which evolved from a long-established radiator manufacturing business, has shifted focus to advanced metal forming. The company now specializes in research and production of lightweight alloy parts, aiming to address common issues in conventional casting such as porosity and shrinkage cavities that weaken mechanical properties.
Its goal is to develop higher-performance materials and processes suitable for demanding sectors where weight reduction and structural integrity are critical. Bole’s thixomolding machines are designed to form magnesium alloys in a partially molten state. This approach reduces internal defects, increases material density, and improves overall mechanical performance compared with traditional casting methods.
Key features include pressure intensification at the end of the molding cycle to eliminate shrinkage cavities in large or complex parts, and hot-runner mold technology that maintains precise melt temperature control, cuts material waste, and boosts part consistency and yield.
The deal covers a full range of machine sizes, enabling Shanxi Xuedong to produce both small precision components and super large structural parts.
The 7,500 ton machine is Bole’s largest announced magnesium thixomolding machine. Currently Bole delivered a 4,000t thixomolding machine which is the largest active magnesium thixomolding amchine in mass production.
TPI First Sample Trial On A 5000 T Machine
Chenzhi Lightweight Technology, a wholly-owned subsidiary of Changan Automobile, has achieved a major milestone by successfully producing the first trial samples of magnesium alloy vehicle structural parts.
The parts were cast on a two-cavity mold using the company’s newly commissioned 5,000 ton die casting unit integrated with a magnesium Thixomolding module.The 5,000-ton machine is equipped with a TPI magnesium Thixomolding module capable of an 18 kg shot weight.
Through innovations in materials, structural design, process parameters, and mold technology, Chenzhi claims to have overcome several critical technical challenges inherent to the magnesium alloy TPI semi-solid die-casting process, including melt control, mold temperature control, and filling stability. These breakthroughs mark significant progress across multiple key aspects of the technology.
Large die casting machines with TPI modules are tracked in The Gigacasting Database.
