Megacasting: Thatcham launches welding certification

Thatcham Research has introduced a new aluminium welding certification designed to help technicians repair increasingly complex vehicle structures, including emerging megacast designs.

The launch comes as vehicle manufacturers continue to adopt lightweight aluminium construction methods to support electrification, improve safety and increase manufacturing efficiency. One of the most significant developments is megacasting, where large sections of a vehicle are produced as a single aluminium casting rather than multiple steel components.

Initially pioneered by Tesla, megacasting is now being adopted more widely across the automotive sector, with manufacturers including Toyota and Ford exploring the technology as part of wider production changes.

Developed by Thatcham Research’s automotive repair specialists, the new course focuses on the practical and technical requirements of aluminium repair. The certification aligns with recognised standards for aluminium joining and repair and includes training in welding safety, equipment setup, bonding techniques and quality assurance.

The programme also incorporates insights from Thatcham Research’s wider work into megacasting repairability, including findings from its 2025 study into the implications of repairing large aluminium cast structures.

That research highlighted that while megacast structures may offer cost-effective repair opportunities in certain scenarios, successful outcomes depend on specialist tooling, updated repair methodologies and a strong understanding of aluminium behaviour.

Graham Keep, Technical Trainer at Thatcham Research and designer of the course, said: “This course has been developed with input from experienced trainers and industry professionals to support technicians and bodyshop staff who want to build both their practical skills and core knowledge of aluminium repair.

“In my experience, many technicians avoid repairing aluminium because they are unsure how it differs from steel or assume the two materials can be treated in the same way. This course is designed to change that.”

Graham added that the training would help delegates understand how aluminium behaves across modern vehicle structures, including the latest use of megacast components.

Dean Lander, Head of Repair Sector Services at Thatcham Research, said: “Megacasting reflects a fundamental shift in how modern vehicles are designed and engineered.

“Our research shows it can deliver benefits in some repair scenarios, but only where repairability is properly understood and planned for.”

Thatcham Research said the certification is intended to help workshops develop a future-ready workforce capable of adapting to evolving repair standards and increasingly sophisticated vehicle architectures.