"The time it takes to cast a large part by melting aluminum alloy through precision molds is only 2 minutes. Tesla has also applied this casting technology in the manufacturing process, but Xiaomi can create larger and stronger integrated parts based on machines that boast greater strength."
A Xiaomi official noted, "If the part has high strength, it can effectively absorb impact during a collision, providing greater safety for passengers. 90.1% of the body of Xiaomi's electric vehicle is made of steel and aluminum, and materials with high strength, enough to be used in submarines, are also employed."
Xiaomi, known as a smartphone and home appliance manufacturer in China, is transforming into a key player in the electric vehicle sector. Although Xiaomi is a latecomer in the electric vehicle market, it is gaining immense popularity, particularly in the domestic market. Following the electric passenger car 'SU7' launched last year, it introduced the electric sports utility vehicle 'YU7' this year, prompting its Beijing plant to operate at 'full capacity' due to surging orders.
On the afternoon of the 28th of last month (local time), I visited the Xiaomi electric vehicle factory. Located in the southern economic and technological development zone of Beijing, the factory spans a total area of 719,000㎡, equivalent to the size of 100 football fields. It was completed 14 months after construction began in 2022. While the interior was noisy from the sound of machinery, it was clean without the unique odors or dust often associated with factories.
Here, processes such as HyperCasting and Press for casting large core components, as well as assembly and painting, were carried out, all performed by enormous robots working diligently on the production line. Many robotic arms from Japan's FANUC were present. Although forklifts operated by humans were occasionally seen, the majority of the component transportation was done by autonomous mobile robots (AMR). The production line was mostly occupied by robots, with human workers only assigned to supervision at the very end of the line. There were no workers visibly sweating with grease on their bodies. Banners with phrases like '100% automatic installation (100% 自动上件)' and 'assembly automation (连接自动化)' were hung high from the ceiling.
Xiaomi was maximizing automation to boost productivity. During the tour of the large component manufacturing process, it took the robots just 25 seconds to cast aluminum alloy. After cooling, cleaning, and polishing, it took approximately 100 to 120 seconds to complete the final parts. Xiaomi explained that the ability to quickly fill molds with strong forces and reliably achieve complex shapes enabled them to maintain faster speeds than competitors. Subsequently, nine robots took 84 seconds to take 28 X-rays, while artificial intelligence (AI) inspected defects within 1 second. Defective products were reintroduced into the furnace for remelting.
As a result, Xiaomi produces casting parts that are about 17% larger than those of Tesla. As size increases, the performance of raw materials becomes more critical, and Xiaomi has developed a patented aluminum alloy material known as "Xiaomi Titan Alloy." This alloy contains a total of 11 elements and boasts balanced strength and elasticity. It also effectively controls weight and expenses. The torsional rigidity of the Xiaomi YU7, which utilizes this material, was recorded at 47,600 N·m/deg. Torsional rigidity refers to the force required to twist the body by 1 degree. Volvo vehicles, known for their stability, are reported to have a torsional rigidity of about 40,000 N·m/deg.
The same goes for pressing. It uses a press to produce about 17 to 18 large panels such as car doors, trunk lids, and fenders, with one panel produced approximately every 2 to 4 seconds. The factory operates two press lines simultaneously.
The large parts produced in this manner are assembled and welded by a total of 419 robots on a production line spanning 70,000㎡. First, several robotic arms simultaneously weld the outer frame and internal panels of the body to complete the basic frame, after which additional welding enhances durability, leading to the door assembly stage.
When the body is placed on the door assembly line, robotic arms bring in the doors and take several photographs to confirm and inspect the assembly positions. Once all checks are completed, screws are tightened to secure the doors. Once four doors are automatically assembled in one position, they are sent up to the second floor for the next process. The core process of the body factory achieved a 100% automation rate, while the overall factory's automation rate reached 91%.
Although I couldn't verify it directly on that day, the painting system is also equipped with one of the industry's highest levels of automation, allowing for color changes in about 40 minutes. For the SU7, painting is done in a maximum of eight processes, which is two more than competitors, boasting superior corrosion resistance that exceeds the industry average.
Xiaomi produces all domestic volumes at this factory. It is capable of producing over 1,000 units per day and can manufacture 150,000 units annually, with a maximum capacity of 240,000 units. As of July, it shipped 30,000 units per month, and the total cumulative shipment over the past 15 months (April 2024 to July 2025) reached 300,000 units.
Xiaomi intends to continue its growth based on research and development (R&D) in advanced technologies such as artificial intelligence (AI). Last year, Xiaomi's R&D investment reached 24.1 billion yuan (approximately 4.7134 trillion won), marking a 25.9% increase from the previous year. The total number of R&D personnel expanded to 21,190. As of the end of last year, Xiaomi held more than 42,000 global patents, of which over 1,000 are related to electric vehicles.