Bühler’s megacasting technology has entered series production in Europe with the new Volvo EX60. At the automaker’s Torslanda plant in Sweden, two Bühler Carat 840 die casting cells manufacture the vehicle’s rear underbody as a single aluminium part, replacing about 100 conventionally manufactured and assembled components. This reduces weight, a key advantage for electric vehicles, helping to lower energy consumption and extend driving range. With the EX60, Volvo becomes the first European carmaker to deploy megacasting technology in series production.
Megacasting uses high-pressure die casting to produce large vehicle-body sections in a single piece. In conventional manufacturing, the same structure consists of several parts that must be transported, stored, assembled, and welded. At Volvo Cars’ Torslanda plant, the EX60’s rear underbody is cast close to the vehicle assembly line. The one-piece design reduces production and logistics steps, contributing to lower weight and greater structural rigidity.
The two Bühler Carat 840 die casting cell
Lower weight is particularly important for electric vehicles, as it can reduce energy consumption and increase driving range. The EX60 is based on Volvo Cars’ SPA3 electric-vehicle platform, which integrates the battery into the vehicle structure as a load-bearing element.
8 400 tons of locking force
The scale of the project is reflected in the dimensions of the die casting equipment used at Torslanda. Each Carat 840 provides 8 400 tons of locking force to keep the mould closed while liquid aluminium is injected at high pressure. The machine can inject more than 200 kilograms of aluminium within milliseconds.
Each casting cell is 7.6 metres high, occupies around 160m², and weighs more than 1 000 tons when fully installed. Delivering the two cells to Torslanda, 12 kilometres from Gothenburg, required 120 truckloads.
The rear underbody is produced using a 130-ton die with modular inserts. Individual sections of the tooling can be changed without replacing the entire die, helping Volvo implement design changes faster.
The Volvo EX60 is another example of how megacasting is becoming an established part of the automotive manufacturing
The project is the result of years of close collaboration between Volvo Cars and Bühler. “The Volvo EX60 represents a significant technological leap for Volvo Cars. We have invested many hours and kilometres in developing the new Volvo EX60, which is one of the most advanced cars on the market. We are particularly proud that the megacasting technology from Bühler Group brings Swiss innovation to this new generation of vehicles. In this way, the EX60 combines our Swedish roots with Swiss technology and demonstrates how international collaboration can help drive the future of electric mobility,” says Jesus Fernandez de Mesa, Managing Director of Volvo Car Switzerland and Head of Central Europe Cluster.
The megacasting cell manufactures the vehicle’s rear underbody as a single aluminium part, replacing about 100 conventionally manufactured and assembled components
From emerging technology to industrial reality
To bring megacasting into series production, Volvo Cars created the industrial conditions needed to operate the technology at scale. They built a dedicated hall at Torslanda and trained specialist teams. The installation is the company’s first in-house megacasting facility and marks the first use of the process within its global production network.
Megacasting extends structural die casting from individual components to complete sections of the vehicle body. The entire process, from melting and die filling to component handling and assembly-line integration, must work as one production system.
“The EX60 is another example of how megacasting is becoming an established part of the automotive manufacturing. As automakers seek more efficient ways to produce electric vehicles, large structural castings are playing an increasingly important part of next-generation vehicle architectures,” says Cornel Mendler.
For further information visit https://www.volvocars.com/za/news/mega-casting-works-in-volvo
