image of an EV cast trimming

Solve automotive cast trimming challenges with robotic plasma cutting

 

Auto manufacturers must excel in quality, efficiency, and cost reduction to stay competitive. Profitability hinges on identifying opportunities to improve efficiency. That's why global auto manufacturers are increasingly adopting giga casting―large-scale frames with one cast―eliminating the need to weld dozens of body parts. Fewer parts decrease vehicle weight, enhance fuel efficiency, and accommodate the growing demand for battery-electric vehicles and more efficient internal combustion vehicles.

Excess material from the mold must be removed once the cast part is extracted from the press. That’s where robotic plasma-cutting technology is helping to revolutionize auto manufacturing.

A robotic system with two robots equipped with Hypertherm plasma decreased cost per unit by 49% versus using a trim press


Challenges facing automotive manufacturers

  • Trim press machines are costly to maintain and result in increased downtime for repairs, parts, oil, replacement die blades, and more.

  • Trim presses generally take up a large footprint and incur high capital costs.

  • Trim presses constrict product design as new press dies are costly and time consuming to replace making it very tedious to implement design changes.

  • Trim presses require the parts to cool down prior to trimming to avoid fractures and deformations which can lead to high scrap rates. This method of cast trimming often requires secondary operations resulting in extended cycle times and cost per unit.

  • Using a trim press results in a large piece of scrap remaining which quickly fills the scrap bin and is hard to handle.

  • Saw blades can only achieve straight cuts resulting in excess material remaining that requires additional time in secondary operations.

  • Skilled labor shortage increases costs and curtails productivity, especially with material removal quality

Art_car_with_parts_Cast_Trimming_image_590x332.jpg

Giga castings are reshaping auto manufacturing—fewer parts, faster builds, and a leap toward EV efficiency.

Robotic Hypertherm plasma-cutting solutions address these challenges

Challenges Solutions
High equipment, die, and operating costs Robotic plasma is generally about 1/3rd of the cost of a trim press. It requires minimal maintenance, has a significant lifespan, and does not require the use of molds/dies
Machine downtime Robotic plasma drastically increases uptime, as it does not need to go down for maintenance and repairs like a trim press
Product design changes Robotic plasma cutting can rapidly be programmed to cut new parts and shapes offering a flexible trimming cell that can accommodate multiple casting designs
Scrap and secondary operations A near net cut on complex shapes can be achieved, reducing the need for secondary operations. The robot can be programmed to trim down the scrap size for better scrap bin usability
Part variation Plasma cutting has a greater tool-to-part distance (stand-off) for collision avoidance
Floor space A plasma cutting robot takes up minimal floor space
Part cooling prior to trimming With plasma, castings can be trimmed and cut while hot reducing production time, avoiding part distortion, and saving energy costs by remelting the scrap hot and quickly

Hypertherm plasma is the trusted choice for auto manufacturers

Hypertherm® plasma systems are designed to easily integrate into robotic cells for cutting cast metal parts, significantly reducing time, labor, and operating costs compared with alternative technologies. Hypertherm has key differentiators from competitive systems and other technologies that make it the choice for leading auto manufacturers—and electric vehicles on the road today.

Hypertherm is the only plasma technology provider that offers a single-piece plasma cartridge consumable that enables automatic changes and eliminates downtime. This patented consumable has built-in RFID intelligence that provides performance data and communicates with the power source to set the appropriate parameters.

The choice is clear

Leading auto manufacturers tested other cutting technologies, including fiber laser, and have found that Hypertherm plasma for aluminum cast trimming is the best solution.

  Robotic Plasma Robotic Waterjet Robotic Fiber Laser
Uptime High Low Low

 

Cut capabilities

Quality and ability to accommodate part variability

 

 

High standoff

 

 

Average standoff

 

 

No standoff, cannot accommodate 
part variation

Operating costs Low High High
Processing time Low High Low

 

Why Hypertherm Associates

With everything we do, we believe in challenging what is thought to be impossible. By fueling imagination―yours and ours―together, we design products that inspire the global landscape and are user and environmentally friendly. Our proven technologies for cutting and shaping help build a more connected and interesting world.

 

We participated at the NADCA Congress & Exposition

Soumya Mitra, PhD and team leader for engineering and cast trimming, presented a technical paper on why degating castings with plasma-cutting robotic cells are more accessible, efficient, and less expensive than traditional trimming methods.

Download white paper


Let’s discuss your cast-trimming needs

Our follow-up process:

Your single point of contact will reach out to understand your project and challenges and organize a follow-up, including direct access to our engineering team, dedicated to cast trimming applications.

Next steps may include: 

  • Product testing

  • Proof of process testing

  • Collaboration between automotive manufacturers and preferred partners

Contact a Cutting Pro