A new study from the U.K. has found that Tesla's innovative "mega cast" technology could seriously reduce vehicle repair costs while also cutting waste and extending vehicle lifespans, according to Repairer Driven News.
Thatcham Research, an automotive testing organization based in Berkshire, England, examined Tesla Model Y vehicles equipped with a single-piece aluminum rear floor section. The design consolidates roughly 70 parts into one casting. Researchers ran two years of crash tests and repair simulations to see how the technology performed.
In low-severity collisions at 15 kilometers (just over nine miles) per hour, the mega cast sustained no structural damage, allowing for complete repair without replacing the large section. Even full replacement costs necessitated by tests for impacts at speeds exceeding 15 miles per hour were less than those for traditional repairs.
As a result, Thatcham concluded that Tesla's approach "can deliver significant benefits for insurers, customers, and the environment," per RDN.
"This finding challenges initial industry concerns about the vulnerability of large single-piece castings to minor impacts," the company wrote in a press release, as reported by RDN. Other automakers, including Toyota, Volkswagen, and Volvo, are planning similar mega cast designs in the near future, according to Thatcham.
For consumers, this new tech could translate to lower insurance premiums and fewer total vehicle write-offs after collisions. Thatcham found that replacing Tesla's mega cast component costs around $978, which is often cheaper than traditional multi-part steel repairs. In some scenarios, repair costs were up to $2,961 lower than those of comparable vehicles.
Lower repair costs keep more EVs on the road, reducing the need for new production. Extending the life cycle of each vehicle preserves the energy and raw materials already invested in manufacturing — and more EVs staying in service means fewer gas-powered replacements.
This development is welcome news for Tesla. The company has seen its global sales growth slow in 2025 compared to previous years, raising questions about how it will maintain its market lead. New cost-saving innovations, such as the mega cast, can help the brand stay competitive.
For current Tesla owners, the study offers some reassurance that cutting-edge design doesn't necessarily mean higher costs after a crash. Still, Thatcham cautions that some repairs will still require Tesla-approved shops, which could add delays or expense in some cases.
As other automakers follow Tesla's lead, mega casting could reshape how cars are built and repaired worldwide, saving drivers big bucks in the process. Charging at home also adds to the savings associated with EV ownership, as it is much cheaper than public charging. Qmerit helps homeowners install Level 2 chargers by offering free, instant installation estimates from trusted pros.
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