Controversy over maintainability of integrated die-casting parts

Controversy over maintainability of integrated die-casting parts
Integrated die-casting combines dozens of parts into one, improving manufacturing efficiency, but the maintenance cost and insurance pricing after collision have become controversial topics.
Benefits on the manufacturing side
Integrated die-casting reduces the number of parts and welding points, improves the rigidity of the vehicle body, and accelerates the production cycle.
High integration of individual components, reduced assembly processes, and decreased labor costs.
These benefits are clear on the manufacturing end.
Problems on the maintenance side
After the integrated component is damaged, it usually needs to be replaced as a whole and cannot be partially repaired like sheet metal parts.
The replacement cost is high and requires large tooling and specialized equipment.
The maintenance network has insufficient capacity and long maintenance cycles.
The impact of insurance pricing
The increase in maintenance costs will be transmitted to insurance rates. As a result, the insurance premiums for some car models have been raised.
The insurance company's loss assessment standards for integrated die-casting vehicle models are still being improved.
This is an industrial supporting issue, not a defect in the process itself.
Design response
Design vulnerable parts as individually replaceable modules through structural partitioning.
Use integrated components in non collision areas, while retaining repairable structures in collision areas.
These plans will increase some weight, but can reduce maintenance costs.
The meaning of mold enterprises
The market for integrated die-casting molds is concentrated in a few large parts with high barriers to entry.
Most mold companies still have opportunities in small and medium-sized structural components, such as steering knuckles, brackets, and battery case frames.
Xinfeng Mold mainly uses low pressure, gravity, and differential pressure on structural component molds, complementing integrated die-casting.
Common Misconceptions
One misconception is that integrated die-casting will completely replace traditional processes. The maintainability and batch limitations determine that it is only suitable for some parts.
The second misconception is to ignore the insurance and maintenance ecosystem. Process selection should consider the full lifecycle cost.
Supporting maintenance network
The maintenance of integrated components requires large tooling and specialized equipment, which ordinary maintenance outlets do not have the conditions for.
Manufacturers need to establish regional maintenance centers, otherwise the maintenance cycle will be very long.
Adjustment of insurance products
Some insurance companies have introduced exclusive terms for integrated die-casting models.
The rate is linked to the maintenance cost of the vehicle model, which forces car companies to optimize their design.
Inspiration for Mold Enterprises
During the mold design phase, maintainability should be considered, such as making vulnerable areas into independent modules.
This type of design will increase the complexity of the mold, but can reduce downstream maintenance costs.
cost allocation
The mechanism for sharing maintenance costs is still being explored, and there is no unified plan for how car companies, insurance companies, and consumers can share them.
This will affect the promotion speed of integrated die-casting in mid to low end car models.
The maintenance training for integrated die-casting needs to be done in advance, as the insufficient capacity of the maintenance network will prolong the cycle.
The supply of spare parts for integrated die-casting needs to be laid out in advance, and if there is a shortage of body parts, the production line will be stopped directly.
The residual value of second-hand cars for integrated die-casting models is affected by maintenance costs, which is a variable being observed in the market.
The maintenance time standards for integrated die-casting have not been unified yet, and there may be differences in insurance loss assessment.
Frequently Asked Questions
Q: Can the integrated component be repaired if it hits?
Answer: It is usually replaced as a whole and difficult to repair locally.
Q: How much is the maintenance cost?
Answer: Significantly higher than sheet metal parts, depending on the vehicle model.
Q: Will the premium increase?
Answer: Some car models have seen an increase in maintenance costs.
Question: Is there a solution?
Answer: The structure is partitioned, and vulnerable parts are made into replaceable modules.
Q: Will it replace all processes?
Answer: No, only suitable for some large items.
Q: Where are the opportunities for mold companies?
Answer: Small and medium-sized structural components are still the main battlefield.
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