Thatcham Research has demonstrated the crucial role of non-destructive testing (NDT) in assessing the structural integrity and repairability of Tesla Model Y vehicles with aluminum mega cast rear chassis sections.
Over a two-year study, the Model Y’s single-piece rear floor, which consolidates around 70 components into one casting, was crash-tested and analyzed using NDT methods to identify hidden structural damage and assess repair options. NDT allowed researchers to detect internal cracks, misalignments, and other defects without dismantling the component, ensuring accurate evaluation of both partial and full replacement scenarios.
Richard Billyeald, Thatcham Chief Research and Operations Officer, said:
“Our research demonstrates that mega cast technology, when properly implemented with comprehensive repair guidelines, can deliver significant benefits for insurers, consumers, and the environment. The Tesla Model Y’s repair costs were consistently lower than comparable vehicles with traditional construction while maintaining structural integrity and repairability standards, which reduces the chances of a vehicle being written off in common accidents, improving its lifecycle CO2 benefits.”
The study underscores the importance of standardized NDT procedures, technician training, and repair protocols as mega cast technology becomes more widely adopted across the automotive sector. Effective NDT not only safeguards structural safety but also optimizes lifecycle costs and sustainability.
