A recent study has challenged traditional concerns surrounding Tesla’s gigacasting technology, highlighting the benefits of large structural castings in vehicle production and collision repairs. The study, conducted by Thatcham Research, found that Tesla’s gigacastings not only streamline the manufacturing process but also make repairs easier and more cost-effective.
Critics have long worried that Tesla’s single-piece castings, particularly utilized in the Model Y and Cybertruck, could lead to expensive repairs in the event of an accident. However, the study revealed that repairs on a Tesla Model Y’s rear gigacast saved nearly $3,000 compared to similar repairs on a Model 3’s conventional multi-part steel body. Even full replacements were more affordable, with the “gigacast sectioning” approach allowing damaged portions of the casting to be replaced without replacing the entire piece.
Wes Morrill, a lead engineer at Tesla who worked on the Cybertruck, emphasized the benefits of simplifying body design with large structural castings. By eliminating the need for numerous smaller parts, welds, and joints, gigacasting not only accelerates assembly but also localizes damage in collisions, making repairs less complex for repair shops and insurers.
These findings come as Tesla expands its global production operations, with Giga Berlin recently hitting milestones in Model Y production and introducing the new Model Y Performance, which relies on gigacasting structures. In China, Tesla launched the three-row, six-seat Model Y L last month, further showcasing the company’s commitment to manufacturing innovations.
As gigacastings become increasingly integral to Tesla’s design approach, the study suggests that insurers and repair shops may need to reassess their perceptions. Rather than posing a repair challenge, Tesla’s bold casting strategy could set a new standard in terms of cost savings and efficiency within the industry.