Hantek, a Chinese manufacturer specializing in lightweight aluminum chassis, has developed a completely new type of chassis that pushes the boundaries of large-scale aluminum casting. This chassis was installed for the first time in the luxury SUV BYD Yangwang U8L, it is the first construction in the world made as a single piece that connects the entire chassis, instead of dozens of smaller parts that are welded or riveted as standard.
The chassis covers an area of about 4 square meters, with walls from 4 to almost 50 mm thick, with a record maximum to minimum thickness ratio of 12:1, something that has not been possible in a single component casting before. This is precisely why numerous joints in traditional aluminum chassis create weak points, reduce the rigidity and long-term durability of the supporting parts of the vehicle.
China gets first one-piece aluminum chassis for electric vehicles
Hantek has advanced the low-pressure casting process so that the aluminum is properly distributed and solidified in both extremely thin and thick parts. The result is an extremely rigid and torsionally strong chassis, which significantly improves safety, comfort and durability. A special aluminum alloy and precise heat treatment further improve the strength and fatigue resistance of the material.
This technology could change the way China manufactures large chassis for electric vehicles and bodies for hybrid vehicles, as the unique cast frame shortens production, reduces costs and eliminates joint weaknesses.
The first model with the new chassis, BYD Yangwang U8L, was launched in September 2025. It is a luxury SUV on BYD’s e4 platform, with a 2.0 turbo engine, four electric motors and a 15.4 kWh battery, with a total power of 1,180 hp and 1,520 Nm of torque. In electric mode, it covers up to 200 km, and even 1,160 km combined, with a chassis that allows the vehicle to remain stable and comfortable despite the enormous power. Hantek’s one-piece chassis thus becomes a technological breakthrough that could define the next generation of construction for electric vehicles, reports Interesting Engineering.