Hantek, a Chinese manufacturer specializing in lightweight aluminum chassis systems, has developed a new frame that expands what can be achieved in large aluminum casting. The company focuses on producing large structural components for automakers, and this latest design addresses long-standing challenges in creating ultra-large, thin-walled parts.
The frame covers a projected area of about 45 square feet, with wall thickness ranging from 0.16 inches to 1.97 inches, resulting in a thickness ratio of more than 12:1 a level of variation that is typically difficult to manage in a single casting process. According to Hantek, it is not aware of any previous project worldwide that has successfully cast a frame with such a wide and precisely controlled thickness range.
The hidden weaknesses in conventional aluminium vehicle frames Instead of relying on a single integrated structure, most all-aluminum vehicle frames are built from dozens of smaller parts that must be welded, riveted, or mechanically joined. Each of these steps adds complexity, cost, and production time. More importantly, the joints created during assembly often become structural weak points, reducing overall rigidity and potentially impacting long-term durability and safety.
Following extensive development work, Hantek succeeded in addressing several technical obstacles associated with low-pressure casting of ultra-large, thin-walled components. Key challenges included managing the flow of molten aluminum during filling and ensuring proper solidification across sections with significantly different thicknesses.
These advances enabled the company to produce a single, integrated aluminum frame that replaces the traditional approach of assembling many separate parts. By combining multiple components into a single structure, the integrated frame design significantly boosts overall body rigidity and torsional stiffness.
The optimized distribution of forces throughout the frame also enhances crash performance. Hantek notes that the use of its specially formulated aluminum alloy, combined with precise heat treatment, delivers a balanced mix of high strength, toughness, and long-term fatigue resistance.
Low-pressure casting could redefine China’s EV frame production Hantek’s low-pressure casting process marks an important step in the production of large, complex aluminum structural components in China. The company notes that this approach could influence the design and manufacturing of large-vehicle frames in the future, offering a more integrated and efficient alternative to traditional multi-part assemblies.
Launched in September 2025, the BYD Yangwang U8L is a full-size luxury SUV, built on BYD’s e4 (Yisifang) platform, and combines a 2.0-liter turbo engine with four electric motors and a 15.4 kWh Blade battery, producing 1,180 horsepower and 1,120 lb-ft of torque. It offers an electric-only range of 124 miles and a total driving range of 721 miles, highlighting the efficiency and endurance of the vehicle. The advanced single-piece aluminum frame not only reduces weight but also enhances structural rigidity, enabling the SUV to handle the immense power from its four electric motors while maintaining stability and comfort over long distances.
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