Unveiling Xiaomi’s Integrated Die-Casting Technology: How is it Achieved?

Have you ever wondered how Xiaomi achieves precision and efficiency in its electric vehicles? The recent fire of Millet SU7 is inseparable from millet’s excellent marketing. In millet marketing, integrated die casting technology is an important highlight. Xiaomi’s integrated die-casting technology is a groundbreaking advancement that’s redefining automotive manufacturing.

This blog post will delve into the innovative process, the materials used, and the significant advantages this technology brings to the table. By the end, you’ll have a comprehensive understanding of how Xiaomi’s cutting-edge approach sets a new standard in the industry.

What Is Integrated Die Casting?

HyperCasting Machine of Xiaomi

Integrated die-casting technology involves using high-tonnage die-casting machines to mold multiple parts into a single component in one casting process. The procedure entails pouring molten metal into a mold, which quickly fills and cools to form an integrated part. This method significantly reduces the number of individual components, simplifies the assembly process, and lowers production costs.

Xiaomi’s integrated die-casting technology is a proprietary development. In January 2024, Xiaomi’s “Super Integrated Die-Casting Technology” won the 2023 Xiaomi Million Dollar Technology Award. Xiaomi’s die-casting machine achieves a clamping force of 9100 tons, surpassing Tesla’s 9000-ton machines in the U.S. and 6000-ton machines in Shanghai, making it a leader in the field.

Development And Innovation Of Integrated Die Casting

While integrated large die casting for electric vehicles (EVs) has recently gained prominence, the technology has long existed. Initially, due to process limitations, integrated die-casting was used for small, relatively simple parts. The application of integrated die-casting in automotive manufacturing was pioneered by Tesla, significantly advancing manufacturing standards.

In July 2019, Tesla unveiled a new patent for a “multi-directional body casting machine for a vehicle frame and associated casting methods.” This method involves placing a fixed mold at the center with four movable molds positioned in different directions. Molten aluminum alloy is injected from the gates of the movable molds into the cavity, where it flows and merges to form a large integrated die-cast part.

Before this, Tesla recruited top aluminum alloy expert Charles Kuehmann from Apple. His team developed an aluminum alloy formula specifically for integrated die-casting, enhancing the stability of Tesla’s die-cast parts.

Tesla’s integrated die-casting process was first implemented at its Texas Gigafactory. For example, the production of the Model Y utilized a 6000-ton integrated die-casting machine. This technology reduced over 70 parts of the Model 3’s rear floor to just two, cutting the production time from 1-2 hours to as little as 45 seconds and reducing manufacturing costs by 40%.

After seeing Tesla’s successful case, companies including Mercedes-Benz, Volkswagen, Volvo, Xpeng, NIO and Ideal have also adopted similar solutions in automobile production.

The HyperCasting Machine of Xiaomi

As we all know, the super large die-casting workshop of millet automobile factory is the most proud technology of Lei Jun. It is one of the five core technologies independently developed by Xiaomi. Xiaomi’s self-developed Hyper Casting machine is a groundbreaking advancement in die-casting technology. This machine boasts a formidable 9100 tons of clamping force, weighs 1050 tons, and occupies an area of 840 square meters. These specifications surpass Tesla’s 9000-ton machine, setting a new benchmark in the industry.

Xiaomi’s HyperCasting machine has revolutionized the manufacturing process for the rear floor assembly of the Xiaomi SU7.

Integrated die-cast rear floor

This advanced die casting machine consolidates what used to be 72 stamped and welded parts into a single die-cast component, produced in just 100 seconds. 

This integration reduces 840 welding points and cuts production time by 45%.

For the vehicle, this results in a 17% reduction in component weight and a 2dB decrease in road noise.

Additionally, it enhances the longevity of the integrated floor, ensuring it can endure over 2 million kilometers of driving—more than ten times the lifespan of traditional floors.

The Super Large Die-Casting Cluster System

Xiaomi’s super large die casting cluster system is an advanced manufacturing setup designed to optimize the production of large, complex components. The system includes essential components like spraying, temperature control, and mold clamping, ensuring precise and efficient operations.

Integrated Die-Casting Cluster System

The cluster system involves nine main processes, such as inspection, cooling, and cutting, which are meticulously coordinated with 433 industrial parameters. These processes are seamlessly integrated with 16 automated assembly procedures, achieving high precision and consistency.

Notably, the system features a visual large model quality judgment system capable of detecting even the smallest defects invisible to the naked eye within 2 seconds. This automated inspection is ten times more efficient and five times more accurate than manual checks, significantly enhancing the quality and reliability of the final products.

Material Science: Xiaomi Titans Metal

Xiaomi has developed a proprietary alloy material known as Xiaomi Titans Metal to meet the stringent requirements of large, lightweight, and durable die-cast components. In collaboration with China’s National Key Materials Laboratory, Xiaomi utilized an AI simulation system to evaluate over 10.16 million formulas. This rigorous process identified the optimal alloy formula that balances strength, toughness, and stability, resulting in the creation of Xiaomi Titans Metal.


High Strength

High Toughness


Impact on Vehicle Performance:

Weight Reduction: Reduces overall vehicle weight, enhancing efficiency.

Noise Reduction: Lowers cabin noise for a quieter ride.

Crash Resistance: Improves safety by enhancing crash durability.

Benefits of Xiaomi’s Integrated Die-Casting Technology

Enhanced Vehicle Rigidity and Safety: Increases structural integrity, providing better crash protection.

Economical Maintenance: Features replaceable anti-collision components, reducing repair costs and complexity.

Reduction in Manufacturing Complexity and Time: Simplifies production by integrating multiple parts into a single component, decreasing the number of steps and accelerating assembly lines.

Weight Reduction: Lighter components contribute to overall vehicle efficiency and performance.

Noise Reduction: Improved material properties reduce cabin noise for a more comfortable ride.

Increased Longevity: Advanced materials and construction techniques extend the lifespan of vehicle components, ensuring durability and reliability over time.


Xiaomi’s integrated die-casting technology is revolutionizing the automotive industry with its innovative HyperCasting machine, proprietary Xiaomi Titanium Alloy, and advanced integrated die-casting cluster system. These advancements result in enhanced vehicle rigidity, safety, and performance, while also significantly reducing manufacturing complexity and costs. Xiaomi is setting new standards in vehicle manufacturing.

Interested in leveraging cutting-edge die casting services for your projects? Contact us today to custom die-cast aluminum parts and bring the benefits of advanced manufacturing to your business.