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Study on Tesla Model Y finds mega casting can lower repair costs

A new study from Thatcham Research has found that vehicles incorporating aluminum mega cast technology can substantially reduce repair costs compared to traditional multi-piece steel constructions. During the two-year study at Thatcham Research’s headquarters in Berkshire, United Kingdom, Tesla Model Y vehicles, which have a single-piece, aluminum rear floor section, were crash tested. Researchers then conducted damage assessments and repair tec…
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Repairer Driven News broke the news in on Thursday, September 18, 2025.
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