Linamar's first gigacasting plant in Ontario redefines the North American EV market

In Welland, Ontario, the upcoming Linamar facility is poised to revolutionise the North American auto parts sector by becoming the region's first gigacasting plant owned and operated by an auto parts supplier. Despite Welland's reputation as a tranquil canal town near Niagara Falls, the city is set to become a hub for electric vehicle innovation with the inauguration of this groundbreaking facility in 2025.

Linamar Corporation stands as an innovative manufacturing enterprise, seamlessly blending cutting-edge technology with profound expertise in manufacturing. This synergy gives rise to solutions that propel the future of vehicles, motion, work, and everyday lives. The company comprises two key operating segments – the Industrial segment and the Mobility segment, both of which are distinguished global leaders in providing manufacturing solutions and are renowned for developing highly engineered products of exceptional quality.

The gigacasting technology, popularised by Tesla and at the forefront of electric vehicle manufacturing, employs substantial high-pressure die-cast aluminium alloy moulding machines. These machines enable the production of entire electric vehicle chassis segments in a single, efficient step. The Linamar plant in Welland is set to elevate the city's status as a focal point for cutting-edge developments in the EV industry.

Gigacasts make EVs lighter, a huge benefit given the additional weight from batteries that EVs carry compared to combustion cars. They are also cheaper, faster and less labour intensive to produce than the steel-component chassis they replace.

Die-cast aluminium moulds were traditionally limited to producing smaller components, but the industry is now rapidly adopting Tesla's technology approach. Linamar's upcoming facility will mark the first gigacasting plant owned and operated by a North American parts manufacturer.

Mark Stoddart, Chief Technology Officer, and Executive Vice President of Marketing at Linamar, said, "15 or 20 Chinese suppliers are looking to put in this type of capacity in China. But from a European and North American standpoint, we're the first."

Stoddart reveals that Linamar's preliminary intentions involve incorporating three gigacast moulding machines, each boasting a clamping pressure of 6,100 tonnes. The production output of the facility is designated for a particular client whose identity Linamar cannot disclose at this juncture. The confidentiality surrounding the vehicle is a cause for concern. However, its official announcement is yet to occur.

There has been a lot of discussion about gigacasting technology lately, primarily because of the efforts of original equipment manufacturers (OEMs). Prominent players like Volkswagen, Subaru, and Volvo have expressed their interest, with Toyota unveiling its gigacast development facilities in Japan earlier this summer. Lexus showcased a prototype gigacast chassis component at the Japan Mobility Show in Tokyo in October.

Takashi Watanabe, the President of Lexus International, stated that gigacasting technology would be a key feature in the upcoming generation of Lexus EVs set to launch from 2026 onwards.

This shift towards gigacasting is part of a broader strategic move by Linamar, indicating its transition from traditional combustion engine vehicles to a focus on electric vehicles (EVs).

Linamar initiated the development of advanced high-pressure die-casting skills on medium-sized presses (ranging from 2,500 to 4,400 tonnes) several years ago, primarily through a collaborative venture in North Carolina. As the success of Tesla's gigacasting approach gained traction, other original equipment manufacturers (OEMs) sought to emulate it, presenting an opportunity for Linamar. Recognizing that many OEMs lacked internal casting expertise, the company expanded its capabilities to include larger presses and proactively pursued a specific customer.

In terms of organizational restructuring, Linamar acquired full ownership of its joint venture partner in the North Carolina facility. Earlier this year, it integrated the North Carolina and Welland plants into a newly established division, the Linamar Structures Group.

In a strategic move to capture additional revenue in the electric vehicle (EV) sector, Linamar also formed an e-axles group and recently acquired a business specializing in battery enclosures.

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