Giga-casting is a new process of manufacturing individual elements of the car structure. This solution allows the use of huge molding presses under very high pressure to create one-piece parts, eliminating traditional assembly steps.

From a manufacturing perspective, this offers undeniable advantages, and it’s the solution Tesla has chosen to produce some of its models, including the rear end of the Model Y. But aside from manufacturing, what about the “After?”

If you have an accident with your Tesla and the damaged part is a single unit with the rest of the structure, will everything have to be replaced (requiring huge repair costs) or are there other solutions?

Control expenses from A to Z

Today, Tesla is working on just that: make it easier and less expensive to repair cars that have been body molded with this famous Giga press. At the same time, remember that the more difficult the car is to repair, the higher the insurance costs will be.

Tesla is investing in research and development to find viable solutions, according to multiple sources familiar with the matter. The idea is to develop innovative repair methods dedicated to these models, the production process of which has been simplified.

The goal is to find effective methods of intervention that will restore the integrity of the “gigapressed” body without increasing costs too much.

More and more Teslas will use this production method

At the moment this only applies to the Y model and only to the rear of the body. But in the future, Tesla intends to democratize this technique, in particular for the Cybertruck, where several even larger machines have been ordered from the Italian company Idra.

For the upcoming Model 2, Elon Musk even plans to manufacture the entire body of the car in one unit to reduce production costs and thus keep costs down.

Other manufacturers are also interested

At the moment, it appears that Tesla is the only manufacturer that is carefully examining the issue of labor costs on cars produced using gigacasting. The reason is simple: They are currently the only ones using this method!

But Hyundai, Volvo, Ford and Toyota in particular are also interested in this production process, attracted by the speed and cost-effectiveness of this new method, which saves time and money… at least until you have to go to the box workshops

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