Setting new standards for large-format structural components
At the Dongfeng Motor
die-casting plant, which is integrated into the , in Wuhan, the transition to series production is imminent. The plant, which covers an area of approximately 47,000 m², is equipped with a 10,000-tonne and a 16,000-tonne die-casting machine. The facilities are designed for the production of large-format structural components using the die-casting process.According to Wu Xiaofei, General Manager of , the integrated die-casting process replaces conventional body structures – which previously consisted of numerous individual parts and welded joints – with three large-format castings. The aim is to reduce the number of components and weld points, simplify manufacturing processes and, at the same time, optimise the weight and structural rigidity of the vehicles. ’s torsional stiffness is set to increase by up to 20 per cent .
The process is based on injecting molten aluminium into the mould at a pressure of around 40 MPa. The cooling time per cycle is approximately 135 seconds. According to the company, the product qualification rate is around 95 per cent, whilst the material utilisation is approximately 96 per cent. The aluminium used is fully recyclable.
The project was launched in November 2024 and accepted in August 2025. In the first phase of development, with an investment volume of around 500 million yuan, an annual capacity of approximately 200,000 lightweight components is planned. A second expansion phase with four additional lines is planned and is set to increase capacity to up to 600,000 components per year. The plan is to manufacture further large-format structural components, including rear floor modules and battery housings for vehicles with alternative drive concepts.
By expanding the die-casting capacities integrated into , Dongfeng aims to integrate modern manufacturing technologies more closely into its own vehicle production and to further develop its industrial competitiveness.