Lexus shows first ‘gigacast’ electric vehicles with new-generation battery tech

The electric Lexus LF-ZC and Lexus LF-ZL concepts have been revealed today at the Japan Motor Show in Tokyo and will be the luxury brand’s first vehicles to use a Tesla-like ‘gigacasting’ production method on an autonomous assembly line. 

Both concepts will form the basis of electric production models – Lexus confirming the LF-ZC (Lexus Future Zero-emission Catalyst), which is similar in size to the previous Lexus IS sedan – for global showrooms in 2026.

An on-sale date for the flagship LF-ZL (Lexus Future Zero-emission Luxury), which is slightly larger than the current Lexus LS sedan but closer in height to the RX SUV, is yet to be announced. 

Global boss of Lexus, Takashi Watanabe, told a round table of journalists in September 2023 that the brand will be, “Fundamentally changing the structure and the production method of the next generation (electric vehicles).”

That production method is now public with a pair of new generation electric vehicle concepts using a ‘gigacasting’ process for a new modular structure as part of that fundamental change.

Gigacasting is a production technique that reduces assembly time and cost and has been widely publicised by electric car maker, Tesla, which has used the technique to build its Model Y electric SUV since 2020.

Tesla uses an aluminium die-cast machine which, through gigacasting, is able to produce much larger structural parts than typically produced in automotive factories. 

News agency Reuters reports Tesla is also using gigacasting to reportedly investigate casting the underbody of an electric vehicle as a single piece. 

The method also eliminates the need for heat treating the aluminium, saving further time and cost.

Reuters reported in June 2023 that brands including Hyundai, General Motors and Geely – which owns car makers including Volvo and its electric offshoot Polestar – have also been investigating gigacasting. 

Toyota, parent company of Lexus, produced its first prototype gigacast vehicle earlier in 2023 at its Myochi, Japan plant after announcing in June 2023 that it would adopt the manufacturing technique.

Now, it has been revealed that the Lexus LF-ZC and LF-ZL will use gigacasting to create a new modular structure that is split into front, centre and rear sections. Lexus says gigacasting has enabled more flexibility in the component layout and therefore look of both concepts, which leads to better interior space – including a flat floor – and superior drivability.

That includes a ‘prismatic’ battery pack that is positioned low and central in the vehicle. The LF-ZC also comes with the promise of approximately ‘twice the range of conventional battery electric vehicles’, and while Lexus hasn’t produced a figure, its current electric RZ SUV in local showrooms has a claimed 395km range. 

Lexus also has a goal of making LF-ZC one of the most aerodynamic production cars in the world, which will help fulfil the promise of significantly greater driving range.

An autonomous assembly line – where the vehicles move without the need for conveyor belts – also improves production efficiency.

In addition to the new hardware and manufacturing methods, the LF-ZL will be use completely new software which will aid charging, among other capabilities, says Lexus.

The new Arene OS software platform will use V2X communication and ‘big data’ to manage power usage and battery levels.

Lexus and Toyota have been criticised for a slow update in electric vehicle technology, though Toyota has defended this approach as it wheels out electric models including the Lexus RZ SUV.