China unveils world's first one-piece cast aluminum frame for EVs
At the 2025 Yangtze River Industry Science and Technology Innovation Conference held on December 2, Hubei Aviation Special Equipment Manufacturing Co., Ltd. officially released the world's first integrated low-pressure cast all-aluminum load-bearing frame.
This breakthrough overcomes the technical limits of ultra-large thin-walled structural parts. The frame spans a projected area of 4.2 square meters (45.2 square feet) with wall thickness ranging from 4 mm to 50 mm (0.16 to 1.97 inches). Traditional aluminum frames are assembled using welding or riveting, which adds complexity, cost, and weak points in structural rigidity.
The new process eliminates the need for dozens of components by casting the entire frame as a single piece. This integrated design improves overall body rigidity and torsional stiffness, while optimizing force transmission to enhance crash safety.
The technology has been first applied to BYD's high-end electric SUV, the Yangwang U8L Dingshi Edition, priced at ¥1.28 million (approximately $180,000). The frame's weight is significantly lower than traditional multi-part assemblies, achieving both safety and lightweight goals.
The aluminum-gold "bone beam" structure features a thickness span ratio of over 12:1, with the thinnest section at 4 mm and the thickest at 50 mm.
Hubei Aviation Special Equipment Manufacturing Co., Ltd. is a Chinese supplier specializing in lightweight automotive chassis systems. The company has developed advanced casting technologies for structural components and maintains partnerships with major automakers including FAW Hongqi, Dongfeng Lantu, NIO, and BYD. Its innovations focus on improving vehicle safety, reducing weight, and streamlining manufacturing processes for electric and high-performance vehicles.
