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Tesla’s new car-building process could be a huge industrial breakthrough

Photo by Loren Grush / The Verge

Tesla is closing in on a new manufacturing process that could significantly reduce costs and increase production of its electric vehicles. According to sources who spoke to Reuters, the new process will enable the automaker to die-cast almost the entire vehicle underbody as a single piece instead of building out about 400 parts using conventional car-building techniques.

Tesla’s current process to build its popular Model Y SUV already involves a unique use of massive, ultra-high pressure presses that can mold both the front and rear parts of the vehicle. Tesla calls this process “gigacasting,” which some experts say is already highly efficient and cost-effective compared to other automakers’ factories. But now Tesla is looking to up the…

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