Giga Casting

RLE Mobility is setting new standards in giga casting and optimising large-format structural components for more efficient production.

Optimised production processes with RLE Mobility - your partner for pioneering vehicle technology

Giga Casting: Precision and efficiency in modern manufacturing

Giga Casting marks a milestone in manufacturing technology. Even before the actual casting process, the challenge lies in the precise design and simulation of the components. The design process plays a crucial role, as each component must be developed in such a way that it both fulfils the structural requirements and can be manufactured efficiently in the casting process. As Giga Casting replaces numerous smaller components with a single, large-format structural component, the demands on tolerances increase considerably. Each component must fit perfectly into the specific vehicle structure, which makes the precision and optimisation of tolerances essential.

This targeted approach enables us to produce large-format structural components with lower weight and minimised complexity. This not only speeds up the production process, but also significantly increases material efficiency. In addition, Giga Casting enables far-reaching cost reductions along the entire value chain. In addition to the obvious savings in production costs, it also offers benefits in areas that are often overlooked, such as joining processes and logistics. In electromobility in particular, giga casting achieves greater range and energy efficiency. The integration of all process steps – from precise design and simulation tests to final casting optimisation – ensures that quality and performance are continuously improved.

Technical benefits of Giga Casting

Reduction of
weight

Through topology optimisation and design space exploration, the use of materials can be minimised without compromising the structural integrity of the component. This is particularly important for optimising the range of electric vehicles.

Reduction of
part complexity

Giga Casting makes it possible to consolidate several components into a single one. This significantly shortens assembly times and reduces potential sources of error at the same time.

Improved component performance

Simulation-based tests are used to optimise the strength, rigidity and crash behaviour of the components. This means that the components not only fulfil the required safety standards, but often even exceed them.

Cost efficiency

Thanks to precise simulations, the risk of failures is minimised as early as the planning phase. This reduces the need for expensive rework, which makes the transition from design to production more efficient.

Integrated processes and simulations for optimised giga casting solutions

Workflow in the Giga Casting process

The Giga Casting workflow comprises a well-coordinated sequence of steps ranging from the development of the 3D design to the final mould design. First, the component design and casting parameters are determined. This is followed by finite element simulations that analyse alternative load cases and crash scenarios. The casting process is then simulated in order to optimise material flows and temperature curves. The mould design is adapted based on the simulation results to ensure efficiency and production quality. These end-to-end processes ensure optimum performance and production quality.

Component development process

Component development begins with the definition of the design space and topology optimisation, which trims the component shape and structure for efficiency. A reduced simulation model ensures precise calculations with reduced computing time. Static and dynamic load case data are fed directly into the simulation in order to map real conditions. By linking design space development and simulation via automated workflows, continuous optimisation can be achieved. The focus here is on reducing component weight while ensuring structural integrity. In addition, repair solutions are considered in our development process in order to avoid expensive total damage in the event of an accident. This includes the development of sacrifice panels, which are specifically designed so that they can be damaged without having to replace the entire component.

Simulation

Simulations are of central importance in the Giga Casting process in order to ensure the performance of components in the early development phase. Our crash simulations analyse the behaviour of components under realistic loads, while stiffness and strength simulations check their structural integrity. Flow simulations help to maximise casting and process quality. Through these precise, simulation-based approaches, we ensure that each component is optimised to meet the specific requirements and enables efficient and error-free production.

Component integrity

In Giga Casting, we attach great importance to precise adherence to tolerances, as any deviation could jeopardise the structural integrity of the component. As numerous smaller components are replaced by a single, large-format component, exact fit is a particular challenge. We simulate tolerances as early as the development phase to ensure that the component is integrated into the vehicle structure with a perfect fit. Our precise simulation methods enable us to identify and optimise possible deviations at an early stage. This guarantees that our components meet the highest standards of stability and safety and that the structural integrity of the vehicle is reliably guaranteed.

Our services in the field of
Giga Casting

Design space exploration and topology optimisation

We offer advanced design analyses to identify the most efficient material usage options while ensuring component performance.

Development and optimisation for production

Our experts work closely with the customer’s production team to optimise the component design. We place particular emphasis on feasibility and minimising technical risks.

Simulation
and
Testing

We use state-of-the-art simulation technology to evaluate critical performance expectations such as stiffness, strength and crash behaviour. These simulations help to ensure that the component fulfils the high requirements in production.