AICE Expert Insights | Chassis Integration Still Needs Breakthroughs in Technology, Cost, and Industry Chain Synergy

2 Guest Introduction / AICE 2025

Rong Xiao, Chief Engineer of Die-Casting Technology at Chery New Energy Vehicle R&D Center, Distinguished Young Expert of the Foundry Branch of the Chinese Society of Mechanical Engineers, and a doctoral student at the School of Materials Science and Engineering, Jilin University. He is dedicated to promoting extreme cost reduction and lean innovation in the casting industry, having led die-casting process development at several Fortune 500 component companies and first-tier vehicle manufacturers. He was responsible for the domestic first 5-core ultra-complex structure project for the 10th generation Accord cylinder head, the domestic first lightweight body die-casting project for GAC Aion LX, the world’s first project featuring an integrated front cabin and rear floor assembly for XPeng G6, the world’s first overall chassis one-piece die-casting project for Chery, and the globally pioneering dual-shot molding technology and "zero inventory" model product island.

Transformation Points

1. Structural Integration

By integrating the battery, motor, suspension, and other modules through integrated design, it reduces the number of parts and connection points, optimizing space layout. It enhances chassis rigidity and safety while reducing assembly complexity, adapting to the trends of lightweight and intelligent design.

2. Material Lightweighting

Using high-strength aluminum alloys and carbon fiber composites, it reduces chassis weight to improve driving range. It promotes material innovation and process adaptation, balancing the need for lightweight and structural strength.

3. Manufacturing Process Innovation

Introducing integrated die-casting technology (such as Tesla's large-scale die-casting) to replace traditional stamping and welding processes, shortening the production cycle. It requires overcoming technical bottlenecks such as large mold manufacturing and thermal deformation control.

4. Intelligent Design

Embedding wire control systems (such as steer-by-wire/brake-by-wire) and sensors, supporting autonomous driving and chassis dynamic adjustment. Through digital simulation, it optimizes design, achieving synergistic innovation in function and structure.

Technical Challenges

1. Process Complexity

Requirements for ultra-large die-casting equipment: forming large, complex structures requires high-precision die-casting machines, imposing extremely high demands on equipment stability, mold life, and process parameter control. Defect control: integrated die-casting can easily produce internal defects such as porosity and shrinkage, which need to be addressed through simulation, process optimization (such as vacuum die-casting), and online detection technology.

2. Material and Thermal Management Issues

The fluidity and solidification shrinkage characteristics of high-strength aluminum alloys must match the die-casting process to avoid cracking or deformation. Large components are prone to residual stress during cooling, requiring optimized mold cooling system design.

3. Design and Validation Challenges

It is necessary to use CAE simulation to predict structural strength, crash safety, and fatigue life in advance, reducing trial-and-error costs. Integrated chassis must meet stringent vehicle safety standards (such as crash tests), with a complex and costly validation process.

4. Repair Cost Controversy

Integrated structures are difficult to repair locally after collision damage, potentially increasing repair costs, requiring new solutions from insurance and after-sales systems.

5. Insufficient Supply Chain Support

Ultra-large die-casting machines and high-temperature resistant mold materials still rely on imports, and domestic alternatives need to accelerate breakthroughs. Recycling and reusing technology for integrated aluminum-based chassis is not yet mature, requiring the establishment of a circular economy model.

For more in-depth research and analysis, please attend the [Aluminum Die-Casting Industry Development Forum] on April 16, 2025, during the AICE Aluminum Industry Expo, where industry experts will share their insights on-site!