Gigacasting is changing vehicle manufacturing

Gigacasting is changing vehicle manufacturing – and repair practices along with it. Helpfully, with ALLDATA Repair, workshops and bodyshops can either replace or repair complex aluminium structures, like those on Tesla models.

The body structure differs from conventional vehicles. The manufacturer promotes the use of gigacastings, large-format structural parts that are made of aluminium in a single casting. This technology makes production more efficient, reduces weight and increases the rigidity of the body – but what happens when it is damaged?

A rear frame, for example, is cast entirely from a single piece of aluminium. While a repair may seem difficult because the material is light and stable but is difficult to weld and strengthen, ALLDATA Repair and OEM Tesla repair data offers a solution.

Solution

Tesla’s guidelines provide precise specifications, with colour-coded diagrams showing which repairs are permitted:

Blue and green areas: Minor welding or straightening work is permitted

Yellow and orange areas: May be repaired within certain limits – in some cases with reinforcement plates

Red areas: Safety-relevant – only a replacement is permitted

Assuming the damaged rear frame falls into the green area, welding and straightening is permitted up to a certain length – but only using cold methods and without heat distortion. 

ALLDATA Repair can provide the technician with both the exact work area and information on permissible materials, structural adhesives and torques for fasteners. As a result, the frame could be repaired safely – without the need for a complete replacement.