Tesla Gigacasting Actually Reduces Repair Costs According to New Study

Sep 26,2025,By LAN

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   A two-year study by UK automotive expert Thatcham Research reveals that Tesla's gigacasting technology significantly lowers repair costs and time, contrary to industry concerns about expensive repairs. The research involved comprehensive crash tests and damage assessments.

1. Repair Cost Analysis

The study shows substantial cost savings with gigacasting:

  • Model Y repair costs reduced by £2,167 ($2,932) vs traditional Model 3
  • Even moderate collisions cost £519 ($702) less than conventional repairs
  • Low-speed impacts (15 km/h): no structural damage requiring replacement
  • Modular components like rear bumper beams cost only £31 ($42)
Collision Scenario Traditional Repair Cost Gigacasting Repair Cost
Partial Repair Standard Cost £2,167 lower
Full Replacement Standard Cost £519 lower
Low-Speed Impact Minor repairs needed No replacement

Tesla Model Y rear cast rail

2. Technical Innovations

Tesla's repair-friendly design approach includes:

  • Gigacast Sectioning technique for partial replacements
  • Bolted connections and bonding instead of complex aluminum welding
  • Only two long welds vs hundreds in traditional bodies
  • Modular replaceable components for common impact areas

3. Industry Impact

The findings could transform insurance and repair industries:

Tesla's approach proves that simplified body design benefits both manufacturing and repair processes, as noted by Cybertruck engineer Wes Morrill.
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