Automotive industry moves from integrated die casting to "die casting + CNC finishing" hybrid route
Integrated die casting was once regarded as the ultimate solution for new energy vehicle manufacturing, but its high die cost (up to tens of millions of yuan for a single set) and the difficulty of repairing have caused many Tier 1 suppliers to rethink. In 2026, the more pragmatic route is "large die casting + partial CNC finishing". This solution first obtains a nearly net formed blank through die casting, and then CNC finishes the mounting surface, threaded holes, sealing grooves and key mating surfaces. Practical cases show that after using the hybrid route, the total manufacturing cost of parts is reduced by 40% -50% compared with full CNC machining, and 20% -30% compared with pure die casting (requiring high-precision molds). The key to CNC finishing lies in die casting allowance control and fixture design. Due to the existence of die casting die-drawing slope and shrinkage deformation, CNC programming requires the use of adaptive tool setting and online measurement. In 2026, leading CNC service providers have developed a dedicated cutting parameter library for die-casting aluminum alloys, resulting in a 30% reduction in machining time. This trend is particularly evident in the new energy vehicle three-electric system housing, chassis suspension parts, and structural battery packs. It is expected that by 2028, more than 60% of new energy vehicle structural parts will use a "die-casting + CNC" hybrid process.
