As vehicle structures evolve – including the growing adoption of megacasting – Thatcham Research has launched a new aluminium welding certification to equip technicians with the practical skills needed to repair complex modern vehicles safely and effectively.
These changes are being driven by safety requirements, weight reduction, electrification and improved manufacturing efficiency. One of the most significant developments is megacasting, a process that produces large sections of a vehicle’s structure as a single aluminium casting rather than traditional multi-part steel designs, reducing component count and improving production efficiency.
Aluminium welding certification
Pioneered by Tesla, megacasting is now being adopted more widely by manufacturers including Toyota and Ford as the industry looks to streamline production and enhance structural performance.
Developed by Thatcham Research’s automotive repair specialists, the new course focuses on aluminium in vehicle construction, preparing candidates for the next generation of vehicle design.
Aligned with recognised standards for aluminium joining and repair, the certification covers core welding skills, safety, equipment setup and quality checks, with additional insight into megacasting informed by Thatcham Research’s own testing and industry work.
That research – including its 2025 study on megacasting repairability – shows that while megacast structures can be cost-effective to repair in some scenarios, this depends on the right skills, tooling and processes being in place. It also highlights challenges, including the need for new collision repair methodologies, specialist equipment and a deeper understanding of aluminium behaviour to ensure safe and effective repairs.
Candidates will develop practical skills, including working safely with specialist welding equipment and heat-sensitive materials, as well as applying correct bonding techniques.
Graham Keep, technical trainer at Thatcham Research, who designed 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.
“Delegates will gain a clearer understanding of aluminium as a material, how it behaves, and how it appears in different forms on the modern vehicle, including the latest trend of megacastings.”
In addition to boosting technician skills and confidence in repairing complex aluminium architectures, workshop managers will also benefit from a future-fit, skilled workforce that can adapt to evolving repair standards in the future.
Dean Lander, head of repair sector services at Thatcham Research, added: “This course offers the UK automotive repair sector vital hands-on insights into key repair techniques.
“Megacasting reflects a fundamental shift in how modern vehicles are designed and engineered. When it was first introduced, there were understandable concerns about its potential impact on repair costs and total loss rates.
“Our research shows it can deliver benefits in some repair scenarios, but only where repairability is properly understood and planned for.”
To learn more about the new aluminium welding certification, or to secure a place, click here to register your interest.
