Lexus to build new electric SUV in China using gigacasting

Toyota plans to produce a new Lexus electric SUV in China starting in 2027, marking a significant departure from its traditional practice of developing major new models in Japan first. The vehicle will be manufactured at the Lexus plant in Shanghai, where construction began in June 2025.

The production process will utilize gigacasting technology, which molds the entire frame into a single piece. This method is expected to reduce the frame weight by up to 20%, improving driving range and performance while creating a stiffer body and simplifying assembly.

Initial production is targeted at approximately 1,000 vehicles per month in the first year, with expectations to scale to tens of thousands by 2028. This strategic shift is seen as a response to the rapid evolution of the Chinese EV market and intense competition from domestic rivals like BYD.