At the integrated die casting plant of Dongfeng Motor in Wuhan, preparations for full-scale production are nearing completion. The approximately 47,000 m² facility is equipped with a 10,000-ton and a 16,000-ton high-pressure die casting machine, designed for the production of large structural components in a single casting process.
According to General Manager Wu Xiaofei, integrated die casting replaces conventional body structures consisting of hundreds of individual parts and welding points with three large cast components. This approach aims to significantly reduce part count and welding operations, improve manufacturing efficiency, lower vehicle weight, and at the same time increase torsional stiffness by up to 20%.
The process is based on high-precision aluminum die casting. Molten aluminum is injected into the mold at a pressure of approximately 40 MPa, with a cycle cooling time of around 135 seconds. Dongfeng reports a product qualification rate of about 95% and a material utilization rate of approximately 96%. The aluminum used in the process is fully recyclable, supporting resource-efficient production.
The project was launched in November 2024 and completed in August 2025. In the first expansion phase, with an investment volume of around 500 million yuan, the facility is designed for an annual output of approximately 200,000 lightweight components. A second expansion phase, including four additional production lines, is planned and is expected to increase capacity to up to 600,000 components per year. Future production will include large structural parts such as rear floor modules and battery housings for vehicles with alternative powertrains.
By expanding its integrated die casting capabilities, Dongfeng aims to further industrialize advanced manufacturing technologies and strengthen its competitiveness in modern automotive production.
