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Tesla's gigacasting process in the Model Y replaces around 170 to 370 parts across the vehicle's body structure depending on the specific combination of front and rear castings:
Rear Giga Casting: Replaces roughly 70 individual stamped, welded, and riveted metal parts with a single cast piece of aluminum.
Front Giga Casting: Replaces another ~70 parts with a single cast component.
Combined Front/Rear & Structural Battery Pack: When combined with the front casting and structural battery pack integration, Tesla eliminated over 170 parts (and eliminated up to 370 individual components and hundreds of spot welds/fasteners compared to the original Model 3 design).
Beyond drastically reducing the part count, these gigacastings eliminated roughly 1,600 spot welds, simplified factory automation, reduced overall body weight, and improved torsional rigidity.