2023 and some insurers have declined to renew policies for electric vehicles (EV). The reason given is that they need more accurate data to price risk accurately. If that's a challenge Tesla and Toyota will pose more of a problem with 'gigacasting'.
That said, it's unclear what the implications of using cast unibodies could be. Casting could theoretically cut costs and weight, but the porosity of cast metals could reduce strength, and therefore safety. Additionally, there is the question of repairability, as cast bodies might be more difficult to fix in the event of major damage, such as a crash. Body Shop Business describes repair options for cast metals as "limited," so it's possible any significant damage could total a vehicle with a cast unibody.
There is already concern amongst insurance customers at the cost of renewing EV coverage and even one-year-old vehicles suffering total loss decisions as a result of battery damage. Insurers better get underwriters looking ahead to this 'gigacasting' trend and the impact auto insurance.
Such a scenario would be to Toyota's benefit however, as an unrepairable car will still need replacement—potentially with a new car. Auto OEMs might look to offering insurance as a service looking at the big picture of mobility services
oyota has reportedly demonstrated a prototype production line for a cast car chassis, made by a process sometimes referred to as "gigacasting." The new manufacturing technique may offer significant production advantages, but could hand consumers the short end of the stick when it comes to the castings' repairability.
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