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Volvo to adopt “Tesla style” megacasts for its next-gen electric vehicles

Credit: Idea Group/YouTube

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The use of Giga Presses may be considered futile and ill-conceived by Tesla skeptics, but it appears that some veteran automakers are currently preparing to adopt the technology for their next generation electric vehicles. First up seems to be Volvo, which recently noted that its Torslanda factory in Sweden, one of the company’s oldest and largest plants, would be shifting to the use of megacasts within the coming years. 

Similar to Tesla, which practically pioneered the use of megacasts by using them for the Model Y, Volvo would be using the massive components for its next-generation electric vehicles. In a statement to Automotive News Europe, Volvo Solution Architect Vehicle Platform Mikael Fermer remarked that the use of megacasts is one of the company’s biggest technological shifts. “This is the biggest technology shift since we switched from wood to steel (for car bodies),” Fermer said. 

Volvo’s Torslanda car plant (Credit: Volvo Cars)

The Torslanda factory is one of Volvo’s most historical sites, having been opened in April 1964. The facility is expected to receive numerous changes during its transition into an electric vehicle factory. A battery assembly plant would be added to the site, which would allow the automaker to integrate battery cells and modules to the floor structures of its upcoming EVs. 

Volvo’s head of engineering and operations Javier Varela noted that the shift to the use of megacasts could result in 75% time savings compared with how large aluminum body components are traditionally put together today. “You avoid the stamping and welding processes and replace them with a megacasting process that is a one-shot injection followed by some tweaks after the injection,” Varela said. 

Varela also noted that ultimately, the use of megacasted parts should allow Volvo to enjoy some sustainability benefits. “All the aluminum that you are injecting is used. You don’t have any scrap like you do with stamping,” Varela added. 

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While exciting, the utilization of megacasts in Volvo’s Torslanda plant is expected to start around 2025. By this time, the factory would likely also be ready to start the full production of the company’s next-generation EVs. Today, the Torslanda plant produces vehicles like the Volvo XC90 and XC60 SUVs, as well as the V90 station wagon. 

Credit: Tesla

Interestingly enough, it is not just Volvo that is looking to adopt megacasts in their future vehicle production. Other automakers such as German luxury car maker Mercedes-Benz is reportedly looking to utilize single-piece casts as well. Mercedes-Benz is reportedly looking to utilize megacasts to form the rear of its EQXX concept, which made its debut in Las Vegas last month during CES 2022. 

Volvo is yet to announce if it is also purchasing Giga Presses from the IDRA Group, the company currently producing Tesla’s machines. That being said, the automaker did state that it was speaking with leading machine manufacturers to help the company make the switch to megacasts at the Torslanda site. No final decisions have been made yet, however, according to a Volvo spokesperson.

Volvo is looking to make half of its global vehicle sales from battery-powered cars by 2025. By 2030, the company plans to be an electric-only carmaker. To help foster and accelerate this transition, Volvo has announced investments totaling over $4 billion over the past two years. 

Don’t hesitate to contact us with news tips. Just send a message to simon@teslarati.com to give us a heads up.

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Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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Tesla bull sees odds rising of Tesla merger after Musk confirms SpaceX-xAI deal

Dan Ives of Wedbush Securities wrote on Tuesday that there is a growing chance Tesla could be merged in some form with SpaceX and xAI over the next 12 to 18 months.

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Credit: Tesla China

A prominent Tesla (NASDAQ:TSLA) bull has stated that the odds are rising that Tesla could eventually merge with SpaceX and xAI, following Elon Musk’s confirmation that the private space company has combined with his artificial intelligence startup. 

Dan Ives of Wedbush Securities wrote on Tuesday that there is a growing chance Tesla could be merged in some form with SpaceX and xAI over the next 12 to 18 months.

“In our view there is a growing chance that Tesla will eventually be merged in some form into SpaceX/xAI over time. The view is this growing AI ecosystem will focus on Space and Earth together…..and Musk will look to combine forces,” Ives wrote in a post on X.

Ives’ comments followed confirmation from Elon Musk late Monday that SpaceX has merged with xAI. Musk stated that the merger creates a vertically integrated platform that combines AI, rockets, satellite internet, communications, and real-time data.

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In a post on SpaceX’s official website, Elon Musk added that the combined company is aimed at enabling space-based AI compute, stating that within two to three years, space could become the lowest-cost environment for generating AI processing power. The transaction reportedly values the combined SpaceX-xAI entity at roughly $1.25 trillion.

Tesla, for its part, has already increased its exposure to xAI, announcing a $2 billion investment in the startup last week in its Q4 and FY 2025 update letter.

While merger speculation has intensified, notable complications could emerge if SpaceX/xAI does merge with Tesla, as noted in a report from Investors Business Daily.

SpaceX holds major U.S. government contracts, including with the Department of Defense and NASA, and xAI’s Grok is being used by the U.S. Department of War. Tesla, for its part, maintains extensive operations in China through Gigafactory Shanghai and its Megapack facility. 

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Elon Musk and xAI donate generators to TN amid historic power outages

The donation comes as thousands of households have gone days without electricity amid freezing temperatures.

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Credit: Tesla

Elon Musk has donated hundreds of generators to Tennessee residents still without power following a historic winter storm, as per an update from Governor Bill Lee. 

The donation comes as thousands of households have gone days without electricity amid freezing temperatures.

Musk donates generators

As noted in a report from WSMV4, the historic storm that hit Tennessee resulted in hundreds of thousands of residents experiencing a power outage at the end of January. Thousands are still living without power or heat in freezing temperatures for up to nine days.

As per TN Gov. Bill Lee in a post on X, Elon Musk and xAI have donated hundreds of generators to assist residents in affected areas. “Tennesseans without power need immediate help. I’m deeply grateful to @elonmusk & @xAI for going above & beyond to support Tennesseans by donating hundreds of generators to fill the gap, & I value their continued partnership to solve problems & support communities across our state,” he wrote in his post. 

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Tennessee officials have stated that recovery efforts remain ongoing as crews work to restore power and address damage caused by the winter storm. The generators are expected to provide temporary relief for residents facing power outages during freezing conditions.

Tesla Powerwalls may follow

Musk publicly responded to the governor’s post while hinting that additional help may be on the way. This time, the additional support would be coming from Musk’s electric vehicle company, Tesla. 

“You’re most welcome. We’re working on providing Tesla Powerwalls too,” Musk wrote in his response to the official. 

Even before Elon Musk’s comment, Tesla had already extended help to affected customers in Mississippi and Tennessee. In a post on X, the official Tesla Charging account noted that all Superchargers in the two states are online, and free Supercharging has been enabled to help those in areas that are affected by persistent power outages. 

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These include Grenada, Tupelo, Corinth, Southhaven, and Horn Lake in Mississippi and several Supercharging sites in Memphis, Tennessee. 

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Tesla-inspired door handles prohibited under China’s new safety standard

The rule effectively ends a design trend pioneered by Tesla and widely adopted across China’s electric vehicle market.

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Credit: Tesla Asia/X

China will ban hidden door handles on electric vehicles starting 2027 under a new national safety standard, forcing automakers to equip their cars with mechanical exterior and interior handles. 

The rule effectively ends a design trend pioneered by Tesla and widely adopted across China’s electric vehicle market.

China bans hidden door handles

China’s Ministry of Industry and Information Technology (MIIT) noted that the new mandatory national auto safety standard on EV door handles will take effect on January 1, 2027. For models that have already received approval and are scheduled for launch, automakers will be allowed to complete required design changes by January 2029.

Under the new rules, exterior door handles must remain operable even in scenarios involving irreversible restraint system failures or thermal runaway incidents in the battery pack. Doors must also be capable of opening even if the vehicle loses electrical power. Interior doors must include at least one independent mechanical release handle per door as well.

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Safety concerns drive rollback

Hidden and electrically actuated door handles have become mainstream in recent years as EV makers pursued cleaner styling and improved aerodynamics. Tesla pioneered the hidden handle design, and it was adopted by most Chinese EV manufacturers in either fully hidden or semi-hidden forms, as noted in a CNEV Post report. Today, about 60% of top-selling EVs in China use the design.

Chinese regulators have stated that the designs pose safety risks, particularly in crashes or power failures where doors may not open from the inside or outside. Authorities cited multiple fatal incidents in which occupants or rescuers were unable to open vehicle doors after collisions.

One high-profile case occurred last October, when a Xiaomi SU7, a vehicle designed to be a competitor to the Tesla Model 3, caught fire following a crash in Chengdu in southwest China. The driver died after bystanders were unable to open the doors. The incident sparked intense scrutiny over the SU7’s Tesla-inspired door handles.

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