Reduced repair expenses revealed through Tesla Gigacastings study
In a groundbreaking development, a recent study conducted by Thatcham Research has challenged long-standing concerns about Tesla's innovative gigacasting technology. The study, which compared partial repairs on a Tesla Model Y's rear gigacast to similar repairs on a Model 3's conventional multi-part steel body, found that collision repairs on Tesla vehicles are not only easier but also more affordable.
Tesla's "gigacast sectioning" approach, which allows damaged portions of the casting to be replaced without scrapping the entire piece, is a key factor in these cost savings. This approach is particularly beneficial for models such as the Cybertruck, which extensively incorporates gigacasting technology.
The study found that localised damage in collisions, a result of the gigacasting approach, reduces complexity for repair shops and fewer surprises for insurers. Even full replacements of gigacast sections saw a cost advantage.
Gigacasting eliminates the need for hundreds of smaller parts, welds, and joints, streamlining vehicle production. This is evident in Tesla's global production operations, with Giga Berlin, for instance, having started production of the Model Y Performance, which uses gigacasting structures. Giga Berlin has already produced 100,000 refreshed Model Y vehicles.
The findings of the study suggest that insurers and repair shops may need to rethink their assumptions about Tesla's gigacasting approach. In China, the new three-row, six-seat Model Y L was launched, leveraging Tesla's gigacasting manufacturing innovations.
The study's lead engineer, Lars Moravy, who was also involved in the development of the Cybertruck, emphasised the potential for this approach to become an industry benchmark for cost savings and efficiency. With Tesla's global production operations expanding, the future of automotive manufacturing could well be shaped by this revolutionary technology.
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