Industry Insights: Gigacasting Poised To Capture 40% of EV Structural Components Market by 2030

TAIPEI, Taiwan - Aug. 20, 2025 - PRLog -- Teamsworld, a digital manufacturing consultancy with decades of hands-on casting aluminum experience, has analyzed a range of global automotive industry data and market studies. Based on this synthesis of credible sources and in-depth production expertise, Teamsworld believes gigacasting will emerge as a dominant manufacturing method, potentially accounting for 40% of the EV structural components market by 2030. This shift is expected to significantly reshape competition among global automakers.

Gigacasting, the process of producing large, single-piece aluminum alloy vehicle structures in one operation, is redefining how electric vehicles are built. By replacing dozens of individual components and complex welding processes, gigacasting offers manufacturers a pathway to achieve unprecedented cost efficiency, improved safety performance, and faster production cycles.

Momentum Continues Despite Strategic Adjustments by Early Adopters
While Tesla recently announced a strategic pause on certain next-generation gigacasting applications, Teamsworld emphasizes that this move reflects a refinement of use cases rather than a retreat from the technology. "Tesla's decision shows gigacasting has evolved from a one-size-fits-all concept into a targeted, strategic tool," said Senior Digital Manufacturing Specialist at Teamsworld. "True competitive advantage comes from mastering the casting process itself, not just acquiring the machinery."

3 Key Drivers Behind Gigacasting's Growth

1. Cost Efficiency – A single gigacast component can replace up to 170 separate parts, reducing production costs by 15–25% and shortening manufacturing cycles by as much as 60%.
2. Performance Gains – Integrated aluminum structures deliver superior crash safety performance while reducing vehicle body weight by up to 20%, improving EV range and energy efficiency.
3. Supply Chain Simplification – Streamlined component architecture reduces supplier complexity, lowers inventory requirements, and mitigates global logistics risks.

Gigacasting's Opportunities for Specialists
Despite its advantages, gigacasting requires advanced expertise in alloy development, mold precision, and process optimization, the capabilities that many manufacturers have yet to fully develop. "The machine is only part of the equation," added Marcus, the COO of Teamsworld. "Success depends on deep technical knowledge in materials science, tooling, and digital integration, where Teamsworld has decades of real-world experience."

Meet Teamsworld at IAA Mobility 2025
Teamsworld will be showcasing its aluminum casting and digital manufacturing expertise at the IAA Mobility exhibition in Munich, Germany, from September 9–14, 2025. Visitors are invited to meet Teamsworld's engineering specialists and explore how Teamsworld can help manufacturers and suppliers successfully integrate casting aluminum solutions into their production strategies.

Register for Free Consultation:https://bit.ly/3UEqRU7
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