RYOBI LIMITED developed and patented a new structure for an aluminum die-cast automotive component for EVs, promoting vehicle weight reduction. By expanding the application of aluminum to suspension components traditionally dominated by ferrous materials, the design reduces weight while maintaining strength in the load direction.
RYOBI LIMITED developed and patented a new structure for an aluminum die-cast automotive component, with the aim of balancing lower weight and strength. To reduce vehicle weight, which directly contributes to extending the driving range of EVs, the company is strengthening the technological foundation for replacing ferrous components with aluminum alloys.
The new structure places a T-shaped reinforcing section aligned with the load direction in a hollow cylindrical component and optimally lays out truss-shaped ribs to support it. This efficiently increases bending strength in the load direction while limiting the increase in overall weight, achieving both the strength and weight reduction needed to replace ferrous materials.
The axle tube concerned measures approximately 90×200×86mm. The core of the technology is that it enables application to high-load areas where the use of aluminum had previously been difficult. RYOBI LIMITED has promoted component integration and weight reduction through die-casting technology, including the early introduction of gigacasting technology in Japan in 2025.
The company plans to expand the new structure beyond axle tubes to other suspension and structural components. Replacing steel materials with aluminum could also improve EV driving performance and reduce manufacturing energy consumption.