Toyota to make EVs lighter, stronger and cheaper by using same methods used to build 2026 Tesla Model Y, Xiaomi SU7

Toyota is getting serious about its EV plans.

The Japanese carmaker will build a new-generation electric car in China using a revolutionary manufacturing process, according to a report in Nikkei Asia.

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This marks a huge shift for Toyota - a brand that has historically developed its new technology for vehicles in Japan before exporting globally.

This time it will develop the technology in China and then potentially bring it back home.

China is a hub for EV manufacturing, with local and now legacy brands.

Toyota is the latest example, although only a small scale at this stage.

What is gigacasting? 

Gigacasting is a game-changer for EV production because it makes cars lighter, stronger and cheaper to build.

Electric cars are heavier than petrol- and diesel-powered equivalents, so reduced weight boosts driving range significantly. 

Gigacasting is a process where a large die-casting machine moulds the body components of a car into a single piece, rather than welding many individual steel parts. 

It could reduce the overall body weight by as much as 20 per cent, while also being cheaper to build overall.

Tesla and Xiaomi were early adopters of the technology, with other brands like Toyota now exploring it.  

Many Tesla Model Y’s feature gigacasting on front and rear underbody elements, while the rear underbody of the very popular Xiaomi SU7 is also produced using a single piece. 

What are Toyota’s gigacasting plans? 

This new EV could be the production version of Lexus' LF-ZL Electric SUV concept revealed in 2023.

Lexus also revealed a sedan concept called the LF-ZC at the same time.

Lexus said at the time both models were designed to be built using gigacasting.

Toyota will begin production of its new Lexus-badged electric car in the first quarter of 2027. 

The brand plans to produce 1000 units each month for the first year, before expanding to tens of thousands per year by 2028. 

If Toyota is successful with its gigacasting project in China, it is likely to be brought back to Japan for mainstream use on its cars to save the company money and time.

Don’t expect to see this Lexus EV in Aussie showrooms any time soon, because Australia is more likely to receive other Toyota vehicles built with gigacasting in the coming years.