A new two-year study by U.K. automotive research organization Thatcham Research shows that gigacasting technology — pioneered by Tesla and now being tested by other global automakers — could reduce repair costs for drivers while also benefiting insurers.
The results are in contrast to the popular belief that gigacastings made repairs more expensive, and mark a significant shift in the way large, single-piece aluminum castings could be viewed in the industry.
Lower Repair Bills for Consumers and Insurers
Gigacastings are massive, one-piece aluminum sections used in vehicle structures, such as Tesla’s Model Y rear underbody. Automakers have adopted the approach to streamline production, but Thatcham’s research shows clear cost benefits in collision repair as well.
The findings, shared in an exclusive interview with Wardsauto, were compiled using real-world insurance claims data and crash tests conducted in Berkshire, England. The study compared repair expenses between vehicles with gigacast elements and those with traditional multi-piece steel assemblies. The results showed savings across both partial and full replacements.
For example, repairing a Tesla Model Y rear gigacast cost £2,167 (C$4,065/US$2,936) less than fixing a Model 3 with conventional steel structures. Even full replacements were cheaper, saving £519 (C$973/US$703) per repair. Similar savings appeared when benchmarking against models such as the Mercedes EQE and Hyundai Ioniq 5.
Repairability by Design
Thatcham’s chief research and operations officer, Richard Billyeald, explained that Tesla has focused on repairability from the beginning:
“The fact that you can section the vulnerable bits of the casting – and Tesla has a specific repair item that wedges in and bolts through, to address the issue of one large unit – that’s the sort of stuff that really makes a difference.”
Low-severity crashes at 15 km/h (9.3 mph) caused no structural damage to the gigacast, while medium-severity collisions at 25 km/h (15.5 mph) required a full replacement. Still, at £716 (C$1,343/US$970), the casting itself proved competitive against traditional repair methods.
Tesla has also developed replaceable rear rail assemblies priced at just £31 (C$58/US$42) each, making minor collision repairs more straightforward.
Challenges for Repair Networks
While the study’s findings are promising, challenges remain. Repairs that require welding on gigacast structures must be performed at Tesla-approved facilities, raising questions about capacity as more automakers adopt the technology. Vehicle transfers between certified shops could increase repair times and costs.
Thatcham’s principal engineer Darren Bright highlighted the simplification compared to traditional panel construction:
“If you imagine 90 separate panels made of aluminum held together with rivets and adhesive… there are a lot of potential points of failure in repair. On the Tesla, you can drill the welds out and add bolted fixings. Really, quite a simple process.”
A Turning Point for the Industry
Despite initial concerns that large castings would prove fragile or costly to repair, Thatcham’s study suggests the opposite. When repairability is factored in at the design stage, gigacasting offers both production and repair advantages.
Billyeald summarized:
“The real lesson here for carmakers and insurers is when the repairability has been considered at the design stage and methods and strategies for repair are implemented as part of that, you get a good result. It’s the thing that Tesla has done well.”
