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You are here: Home / News / Thatcham Research Finds Tesla’s Mega-Cast Parts Can Cut Repair Costs

Thatcham Research Finds Tesla’s Mega-Cast Parts Can Cut Repair Costs

September 30, 2025 By CollisionWeek Editor Leave a Comment

Two-year study challenges early insurance industry concerns about large aluminum castings as other vehicle manufacturers plan to adopt the technology.

Tesla’s large-scale aluminum casting technology can reduce repair costs compared to traditional steel structures when properly designed, according to a two-year study by UK-based Thatcham Research released Thursday.

The UK automotive research organization crash-tested Tesla Model Y vehicles to assess the repairability of “mega cast” rear floor sections, which consolidate about 70 individual components into a single aluminum casting. The findings counter early insurance industry concerns about potentially high repair costs for the large single-piece structures.

Thatcham Research found partial

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Filed Under: News Tagged With: Hyundai, OEM Repair Procedures, Tesla, Thatcham Research, Total Cost of Repair, Toyota, Volkswagen, Volvo

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