Integrated rear floor casting
A factory learns to cast the floor
Large aluminium castings can consolidate a vehicle’s structure, changing both the factory process and the approach to repair.
Canvas of Knowledge · 14 November 2026 · Illustrated explainerChinese example
Xiaomi’s HyperCasting process produces an integrated rear floor. Its published description also includes detachable crash structures rather than treating every impact as damage to one indivisible component.
European parallel
Volvo describes an EX60 rear floor made through high-pressure aluminium casting at Torslanda. Its design includes repair zones selected according to crash severity.
The engineering trade
Part consolidation can simplify assembly, but alloy quality, die design, defect inspection and repair procedures remain crucial. A press’s tonnage describes clamping force, not car weight.
THE IDEA TO KEEPThe achievement is a manufacturable, inspectable and repairable structure—not simply a larger casting machine.
Different companies. Related engineering.
EX60 rear floor mega casting
Examples identify a shared engineering theme; specifications, implementation and availability differ by vehicle and market.
Sources & further reading
Sources reviewed 14 November 2026. Specifications and availability depend on the product, market and date. Source organisations do not endorse this website.