Lexus is preparing to produce a new electric crossover SUV in Shanghai using large-scale gigacasting technology starting in autumn 2027. The project will mark one of the first times Toyota Motor Corporation, the parent company of Lexus, deploys advanced aluminum casting methods for its electric vehicles.
The upcoming vehicle will be built at a new Toyota manufacturing facility in Shanghai, China. Under the production process, Lexus will adopt gigacasting, a technique popularized by American automaker Tesla that forms large sections of the vehicle body from a single aluminum casting. This method replaces dozens of individual stamped metal parts with one unified structure, reducing the number of assembly steps needed on the factory floor.
By streamlining structural components, the process can lower total vehicle weight. For electric vehicles, reduced mass lowers energy consumption during driving. According to industry reports, applying gigacasting could increase the driving range of the new Lexus model by several percent due to weight savings. Additional modern production methods will also be integrated into the Shanghai facility, though specific details remain undisclosed.
Chinese market strategy
The decision to launch gigacasting in China marks a departure from traditional corporate practice for Toyota. The Japanese automaker historically introduces its newest manufacturing techniques at facilities in Japan or the United States before expanding them elsewhere. However, Toyota is shifting focus to China due to escalating competition in the Chinese electric vehicle market, where Lexus currently lags behind domestic manufacturers.
At present, the Lexus RZ crossover is the only fully electric model offered by the luxury brand in China. Initial production of the new crossover will begin at a modest scale of approximately 1,000 vehicles per month during its first year of operation. Lexus plans to scale up assembly to tens of thousands of units annually as production matures.
Vehicle details and availability
China is expected to serve as the primary market for the new vehicle, and industry reports suggest the model may not be sold outside the Chinese market. Official specifications, including the vehicle name, battery capacity, electric range, and electric powertrain performance, have not yet been announced.
