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Using sand cores, the weld-able, hollow die-cast parts have been developed. For casting, the transition flow filling method is applied to reduce gas containment and to minimize damages to the core. In designing the products, the newly developed core stress prediction system by melt pressure distribution and the newly developed in-product gas containment prediction system have been applied. The hollow die-cast frame made by the new method attains a 30% increase in rigidity and 1kg reduction of weight.

In motorcycles, the materials of frame have been switched from steel to aluminum for the purpose of reducing weight while improving the rigidity of chassis. It was made possible to use aluminum frames for a number of commodity categories, by the development of technology through new structural designs to make the most of the characteristics of aluminum, the advancement of computer simulation system and the progress in material and production engineering. As the result of adopting aluminum for the frame, much higher performance has been realized by achieving a 40% reduction in the developed frames consisting of extrusions and castings for sports-oriented motorcycles and by suppressing the increase in fuel consumption. For low-priced utility vehicles such as scooters, the manufacturing process has been simplified by the development of the die cast two-split module frame.