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Toyota Motor Corporation (Toyota) recently held a technical briefing session, “Toyota Technical Workshop,” under the theme “Let’s Change the Future of Cars” and announced a variety of new technologies that will support its transformation into a mobility company.
Hiroki Nakajima, Executive Vice President and Chief Technology Officer, explained Toyota’s technology strategy and the direction of future car manufacturing. In addition, he spoke on specific and diverse technologies, including concepts under development, which will help achieve the vision and policies that have been communicated so far. Also speaking were Takero Kato, who has been appointed president of the newly established BEV Factory, and Mitsumasa Yamagata, who is scheduled to be appointed president of the Hydrogen Factory to be launched in July 2023. They elaborated on their respective strategies for the battery EV and hydrogen businesses.
On the manufacturing axis, the car body will be constructed from three main components in a new modular structure. Adopting giga casting will allow significant component integration, which contributes to the reduction of vehicle development costs and factory investment. In addition, self-propelling production technology will reduce the processes and plant investment by half.
Japanese car group Toyota Motor Corporation has shown the first giga casting that will help it achieve a lower cost of manufacturing for upcoming all-electric vehicles based on an all-new architecture that will come to market in 2026.
From the video embedded above and the single photo released by Toyota, it appears that the Japanese automaker has made a giga casting for the rear section of a vehicle, similar to what Tesla is doing for the Model Y and the upcoming Cybertruck.
The Aichi-based group has said in the past that it will take inspiration from Tesla’s manufacturing processes, such as the use of giga presses, to simplify production and ultimately lower costs and increase its profit margins.
Although Toyota didn’t mention the differences between the old rear section and the new one, we can make out from the photo that the previous iteration was made up of at least 33 different components, while the giga casting is just one big piece of metal, which the Nippon manufacturer says will help dramatically reduce the number of processes involved during production, as well as the necessary investments.
In the official release, Toyota mentions that the new EV platform will have three main components that make up a modular structure front, centre, which houses the battery pack, and rear section.
The first EV based on the new, purpose-built architecture will debut in 2026 under the Lexus brand, with a next-gen lithium-ion battery that will enable a driving range of over 965kms, according to Toyota Motor Corporation.
The next step in the company’s plan to become “the world leader in batteries” is scheduled for 2026-2027 and involves the development of a bipolar lithium iron phosphate battery that can reduce costs by 40 per cent compared to the previous iteration, while an advanced bipolar lithium-ion battery with 10 per cent more range is scheduled to go into production in 2027-2028.
However, the biggest claim in Toyota’s new electrification plan is an advanced solid-state battery pack that will arrive after 2028 and will offer a range of over 1 448kms on a full charge.
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