Revolutionizing Automotive Manufacturing: The Rise of Domestic Cold Connection Technologies in China’s Lightweight Vehicle Industry

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Body Connection Technology Marks a New Era of Domestic Substitution

Tong Gaosheng | 2025-04-28

As the penetration rate of new energy vehicles (NEVs) surpasses 40%, the Chinese automotive industry is undergoing a significant transformation driven by a material revolution. The composite application of lightweight materials such as aluminum alloys, high-strength steel, and carbon fiber has increased the complexity of traditional welding techniques. Consequently, methods like Self-Piercing Riveting (SPR) have emerged as key technologies to address the challenges of joining dissimilar materials. Meanwhile, the recent unveiling of the Xiaomi SU7 production line, featuring high-speed SPR equipment, has garnered considerable interest from both industry insiders and outsiders.

As a leader in the SPR field, Gujide Intelligent is the only domestic company to have successfully implemented mass production applications across multiple OEMs. In early 2024, it received investment from Xiaomi, signaling the start of a domestic wave centered around body connection technology.

Automotive Lightweighting Creates a New Battlefield in Intelligent Manufacturing

Driven by the rapid development of the NEV industry, the Chinese automotive sector is undergoing an unprecedented structural restructuring. In the past five years, as the penetration rate of NEVs reached a critical turning point, vehicle lightweighting has become a strategic focus for addressing range anxiety, optimizing energy consumption, and achieving carbon neutrality. According to a sample survey of Chinese passenger cars, reducing vehicle weight by 10% can enhance fuel efficiency by 7.5% to 9%, while a 10% weight reduction in pure electric models can directly translate into a 5.5% increase in range. This principle of energy conversion has been quantified in the New Energy Vehicle Industry Development Plan (2021-2035) and Energy Conservation and New Energy Vehicle Technology Roadmap 2.0 with specific lightweighting technical indicators.

The revolution in material science has sparked waves of change in body engineering, with traditional steel’s dominance gradually being challenged by steel-aluminum composite structures. Recent research indicates that the penetration rate of steel-aluminum mixed bodies in high-end NEV models in China has surpassed 60%, with some models utilizing aluminum up to 40%. Vehicles like the Tesla Model Y and NIO ET5 have achieved weight reductions of 15% to 20% through the combination of aluminum body components and high-strength steel frames.

Moreover, the rise of integrated die-casting technology is further reshaping the logic of body manufacturing. Tesla’s pioneering approach consolidates 70 stamping parts of the Model Y rear floor into just 1 to 2 large die-cast components, reducing production cycles from 120 minutes to 180 seconds, while cutting the number of body connection points by over 70%. This “die-casting island” process has quickly led to industry-wide imitation, with the Xiaopeng G6 extending die-casting technology to both front and rear sections, and the Xiaomi SU7 achieving a remarkable 72-in-1 integration in its rear floor die-casting, which is 17% larger than Tesla’s and reduces 840 weld points, resulting in a 17% weight reduction.

The Silent Revolution Behind Multi-Material Composite Structures

The widespread adoption of multi-material composite architectures represents a silent revolution in connection technology. The high thermal conductivity of aluminum alloys, the chemical reactivity of magnesium alloys, and the anisotropy of carbon fiber together create a challenging scenario for traditional spot welding. Although the number of connection points for large die-cast parts and dissimilar materials has been significantly reduced, the strength and stability requirements for the remaining connection points have increased exponentially. This technical paradox has led to a reevaluation of the value of cold connection technologies, with SPR and FDS methods evolving from alternatives to essential core processes.

For example, SPR technology uses a servo motor to drive rivets through the materials to be joined, achieving connection without pre-punching, while perfectly preserving the integrity of surface coatings. This method provides high connection strength, excellent sealing properties, and strong adaptability to various materials. FDS technology also showcases unique advantages in connecting enclosed cavities, with the Xiaopeng G6’s roof longitudinal beam and Zeekr 001 battery pack utilizing this technology extensively. Reports indicate that by 2024, SPR and FDS cold connection processes will be widely adopted in high-end luxury passenger vehicles, with the Jaguar I-PACE achieving 87% of its dissimilar material connections through SPR.

The Future of Body Architecture and Material Composition

Looking ahead, the body architecture is evolving into a hybrid modular design that combines steel-aluminum structures with localized die-casting methods. Industry forecasts suggest that the distribution of mainstream new materials will stabilize at 40% steel, 45% aluminum, and 15% composite materials. This shift will place greater demands on the precision, efficiency, and reliability of riveting technologies and will drive continual upgrades of cold connection processes like SPR and FDS.

It is clear that in this wave of material evolution and technological transformation, the entities that first master and optimize new connection technologies will gain a competitive edge in the lightweighting race of new energy vehicles.

Breaking Through Technological Barriers: The Rise of Domestic Equipment

Despite being labeled as “new connection” processes, the application of SPR and FDS technologies in the automotive industry dates back further than many realize. The introduction of the all-aluminum body frame by Audi in the 1990s was groundbreaking, incorporating SPR technology and establishing a foothold for European and American automakers in lightweight connection technologies. However, as the global automotive industry entered a phase of lightweight competition, this technological revolution faced unique industrial time lags in China.

By 2020, China’s aluminum usage per vehicle had yet to surpass the 190 kg target set by policy, highlighting a stark contrast between the lagging development of the lightweight industry chain and the rapid growth of the NEV market. Investigations reveal that the early domestic SPR equipment market was dominated by European and American giants such as STANLEY-Tucker, Atlas Copco-Henrob, BOLLHOFF, and TOX, while the FDS sector was characterized by a duopoly between Weber and Klingel. The resulting technological blockade led to high costs for equipment procurement and key consumables, along with lengthy process debugging cycles that severely hindered the platform development of smart electric vehicles.

The complexity of overcoming technological challenges extends beyond mere mechanical manufacturing. The core technology of SPR relies on the precise coupling of rivet deformation control algorithms with mold parameters to achieve high-strength connections in heterogeneous materials like cast aluminum and carbon fiber. While traditional imported equipment is known for its stability, it struggles to meet the growing lightweight demands of domestic automakers, particularly given the frequent issues of cracking at aluminum rivets and poor connectivity with ultra-high-strength steel. The lack of localized solutions exacerbated these challenges. FDS technology, due to its single-sided connection process and intricate cavity structures, faces even greater hurdles in breaking through the equipment design and process patent barriers imposed by German companies.

Fortunately, after years of persistent efforts and technological breakthroughs, domestic cold connection equipment manufacturers have finally reached a pivotal moment of transformation. Innovative companies like Gujide Intelligent have upgraded their proprietary SPR systems through three significant technology iterations, evolving from the initial model to a 3.0 version featuring intelligent monitoring, data analysis, and remote operation capabilities. Their group control technology, backed by a vast database of process parameters, enables remote monitoring of equipment status, dynamic parameter optimization, and fault prediction. Through intelligent predictive maintenance and process matching, they have accelerated product rollouts and shortened design cycles.

Recently, in applications with major manufacturers, Gujide Intelligent has optimized rivet gun designs and developed rivet molds compatible with new materials, successfully extending the lifespan of a single device to over 2 million cycles, becoming the first domestic equipment manufacturer to achieve this milestone. This success stems from the accumulation of extensive R&D and engineering talent, along with predictive analysis of technological maturity curves and industry ecological positioning, enabling a forward-looking strategic approach aligned with the correct development trajectory.

The market balance is undergoing a fundamental shift. Research indicates that by 2024, the number of domestic SPR devices is approaching 10%. Gujide Intelligent’s shipment volume surged by 210% to 165 units, establishing direct competition with imported brands on production lines at leading automakers like Geely, Xiaopeng, and Great Wall. By 2024, the total shipment volume of SPR devices in the domestic automotive sector is expected to reach around 1,000 units, with Gujide Intelligent capturing nearly 15% market share with over 150 units shipped annually. Domestic manufacturers account for about 200 units, with an impressive 80% share among local companies, ranking first in the sector.

Notably, the company is leveraging a dual-driven model of “intelligent equipment + process innovation” to transition from lightweight material connection technology and high-end processing purification systems to high-end intelligent manufacturing platform enterprises. In the automotive manufacturing sector, they are building a comprehensive technological matrix that encompasses all connection processes while simultaneously extending their reach to welding smoke dust extraction systems, aluminum alloy polishing dust removal workstations, integrated die-casting environmental dust extraction, and intelligent disassembly lines, forming a comprehensive process solution for the entire automotive manufacturing chain.

Currently, their technological network has deeply penetrated the automotive industry, serving most domestic vehicle manufacturers and leading parts groups. While consolidating their presence in the automotive main channel, the company is also focusing on independent and controllable intelligent connection technology platforms. They are delving into lightweight cold connection processes for new energy vehicles, developing innovative solutions suitable for integrated CTC battery chassis and multi-material body connections. In addition, their new production base in Shanghai is set to enhance production capacity significantly upon completion. Through an ecological layout of “vertical specialization + horizontal industrial collaboration,” the company is gradually evolving into a globally leading intelligent connection technology service platform, with their technological spillover effects already reaching overseas markets, laying the groundwork for a global service capability matrix.

From Technological Blockades to Strategic Breakthroughs

The rise of domestic equipment manufacturers in the SPR and FDS fields not only validates the value of independent innovation but also suggests the possibility of the Chinese automotive industry overtaking in the core process equipment sector. When domestic SPR and FDS devices are applied in mass production on NEV assembly lines, a new era of automotive manufacturing driven by local technology will have begun.

Deep Water Game: The Evolution of the Local Supply Chain

In recent years, amidst the profound adjustments in the global economy and the tide of industrial transformation, the Chinese automotive industry is undergoing a critical transition from scale expansion to high-quality development. In the face of geopolitical struggles, technological embargo risks, supply chain restructuring pressures, and new trade barriers like carbon tariffs, constructing a modern automotive industry system that is independently controllable, secure, reliable, and competitive has become a strategic imperative for the industry’s survival.

In this complex scenario, domestic cold connection equipment manufacturers are seizing unprecedented strategic opportunities. With precise control over comprehensive production costs and the autonomous guarantee of supply chain security, domestic SPR and FDS devices are continuously overcoming technological challenges and redefining the industry competition landscape. For example, following the positive outlook from investment capitals like Xiaomi and Huichuan at the end of 2023, Gujide Intelligent recently received the “Technology Small Giant Project” award from the Shanghai Science and Technology Innovation Action Plan for 2024 and is nearing completion of a Series B financing round led by industry capital. This reflects the high recognition of its strength and development prospects from both the government and the market.

This model of “capital injection + policy empowerment” will provide Gujide Intelligent with strong momentum for technological innovation and R&D, facilitating its leap from “domestic substitution” to “technology leadership,” and accelerating its progress towards the goal of becoming a globally leading equipment enterprise. Gujide Intelligent’s success not only demonstrates the significant advantages domestic supply chain companies have in reducing production costs but also showcases their ability to provide a solid barrier for domestic automakers in ensuring supply chain security, leading to a surge in orders and partnership intentions.

Among these partnerships is the breakthrough into Taiwan’s lightweight body sector, achieving a “zero” breakthrough for SPR technology applications in the region. This cross-strait technology transfer not only verifies the adaptability of domestic equipment in tropical marine climates but also signifies that Chinese body connection technology is beginning to participate in the global value chain. According to industry sources, Gujide Intelligent’s SPR equipment business is expected to continue its growth momentum this year, further solidifying its leading position in the domestic body connection equipment market.

With the intensifying domestic and international competition and increasingly stringent regulatory standards in the global market, the trend of Chinese automakers “going global” has become irreversible. Research indicates that by 2025, the scale of passenger car exports from China is projected to increase by approximately 540,000 units, reaching 5.5 million, while the overseas production capacity of Chinese self-owned brands is expected to surpass 3 million units, forming a new force for Chinese automakers abroad. This development necessitates that automakers align their product quality and technical performance with international standards and emphasizes that the export of technical standards will become a critical area of international competition.

The cases of Gujide Intelligent’s SPR equipment servicing the Taiwanese automotive market and Yipulai’s FDS technology entering Hyundai’s Ulsan plant exemplify the strategic shift of local equipment enterprises from rule followers to standard setters. This spillover effect not only accumulates valuable overseas adaptation experience but is also gradually forming a technology ecosystem aimed at global markets, providing robust support for upgrading domestic industries and exporting international standards for lightweight material connection technology.

Research indicates that by 2024, the total shipment volume of SPR devices in the automotive sector globally is expected to reach around 4,300 units, with Gujide Intelligent capturing nearly 4% of the market share. In the long term, as the local supply chain gradually emerges from the dual tests of technological blockades and market competition, it is stepping away from a stage of reliance and following, moving toward a new journey of independent innovation and global output.

To maintain a competitive edge in the ever-changing international market, it is essential to continuously deepen R&D investment, optimize industrial collaboration, and build a secure and efficient supply chain system. The current strategic opportunity period calls for not only equipment manufacturers to enhance their comprehensive capabilities but also the entire industry to work collaboratively to address technological bottlenecks and supply chain vulnerabilities, laying a solid foundation for China’s automotive industry to secure a larger voice and market share in the global arena.

Conclusion

In just five years, China’s new energy vehicles have achieved a technological leap that traditional automakers would typically require fifteen years to accomplish. The domestic substitution of body connection technology carries significance that extends far beyond mere supply chain security. This industry transformation driven by lightweighting is bypassing traditional technological path dependencies, achieving qualitative change from following to running alongside. As the global competition in smart electric vehicles enters the “deep water” phase, this industrial revolution, which began with the tip of the riveting gun, may reshape the power dynamics of global automotive intelligent manufacturing.