Integrated die-casting

Integrated die casting (IDC) is a variation of traditional die casting. In this process, liquid metal is poured into a mold to form a specific shape. Once the metal cools, a complete part is created without the need for welding or further manufacturing.

However, IDC differs from traditional die casting in several key ways. IDC components are generally larger, require stronger clamping forces, involve more complex mold manufacturing, and utilize different materials. The goal of IDC is to reduce manufacturing costs through one-time molding, significantly decreasing the number of parts needed for car assembly and improving overall efficiency.

This new process offers several advantages but also has areas that need improvement. Elon Musk first proposed and implemented IDC as part of Tesla's Giga Press program.