As it prepares for its new products, factory engineers will also introduce a slew of manufacturing techniques for the 2026 EVs. Their goal is to halve the number of production processes, halve the amount of plant investment and halve the amount of production lead needed to set up for new nameplates.
The new techniques will include the use of giga casting, which eliminates the countless parts and brackets by essentially casting the vehicle’s front and back as two giant modules.
The under-rear section of the current Toyota bZ4X, for example, is a complex amalgam of 86 parts manufactured through 33 processes. But Toyota is prototyping a way to stamp the same multi-part module as a single piece from one process, thanks to the use of a giga press.
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