AuraMaia Group’s Non-Ferrous Casting Technology Center today announced a significant manufacturing breakthrough, having successfully developed and validated a proprietary low-pressure casting (LPC) process for ultra-large, integrated battery tray assemblies. This innovation directly addresses the automotive industry’s pressing need for lighter, stronger, and more cost-effective structures for electric vehicles (EVs).

The center’s latest achievement centers on the production of single-piece aluminum battery tray castings measuring over 2.2 meters in length. Utilizing its advanced simulation capabilities, the engineering team solved critical challenges related to filling uniformity and thermal stress management across such a large surface area. The result is a structural component that reduces weight by approximately 15% compared to traditional multi-part fabricated designs, while improving overall torsional stiffness—a key metric for vehicle handling and safety.

“This breakthrough is a testament to our integrated approach,” said, Senior Process Engineer at the center. “From the initial digital twin and alloy selection to the final heat treatment recipe, every parameter is controlled and optimized in-house. We’ve moved from making parts to engineering the foundational platform of the vehicle itself.”

The successful development is already transitioning to volume production within AuraMaia’s 41,000 m² dedicated casting plant, which houses 16 low-pressure casting machines. This scalable manufacturing capability positions AuraMaia as a leading Tier-1 supplier for next-generation EV platforms seeking to leverage the benefits of megacasting technology without the extreme capital expenditure associated with giant high-pressure die-casting (Giga Press) cells.

The center’s research portfolio continues to expand, with active projects in recycled material streams for sustainable casting e advanced thermal management systems cast directly into motor and power electronics housings.

About AuraMaia Group
AuraMaia is a vertically integrated manufacturing group specializing in engineered vibration control solutions and high-integrity castings. With multiple production bases spanning over 50,000 square meters, the group serves global clients in the automotive, commercial vehicle, and industrial machinery sectors, delivering from concept to volume production.