China's BYD, Hantek launch 'World-first' one-piece aluminium EV frame

Chinese manufacturer Hantek has developed a groundbreaking one-piece aluminum frame for electric vehicles (EVs), marking a significant advancement in large aluminum casting technology. The frame, covering about 45 square feet with wall thickness varying from 0.16 to 1.97 inches (a thickness ratio exceeding 12:1), overcomes longstanding challenges in producing ultra-large, thin-walled parts through low-pressure casting. Unlike traditional all-aluminum vehicle frames, which are assembled from numerous smaller parts joined by welding or riveting—introducing complexity, cost, and structural weak points—Hantek’s integrated casting method creates a single, robust frame. This innovation enhances body rigidity, torsional stiffness, and crash performance by optimizing force distribution and eliminating joint-related vulnerabilities. This new casting process represents a major step forward for China’s EV manufacturing, potentially reshaping how large vehicle frames are designed and produced by offering a more efficient, integrated alternative to multi-part assemblies. The frame is featured in the BYD Yangwang