Thatchman rolls out aluminium welding certification for complex vehicle repair technicians

Stock image for referential purposes only

Thatcham Research has launched a new aluminium welding certification programme aimed at helping vehicle repair technicians work on modern aluminium vehicle structures, including megacast components.

The certification has been introduced as vehicle manufacturers increasingly adopt aluminium-intensive designs and megacasting techniques to improve manufacturing efficiency, reduce weight and support electric vehicle development.

Megacasting involves producing large sections of a vehicle body as a single aluminium casting instead of using multiple steel components. The process, first associated with Tesla, is now also being adopted by companies including Toyota and Ford.

To know the long-term bauxite market forecast, book our report: “Global Bauxite & Alumina Market Forecast to 2036: Supply–Demand, Trade Flows & Price Outlook”

According to Thatcham Research, the new course focuses on aluminium vehicle construction and repair methods required for newer vehicle platforms.

The certification covers aluminium welding techniques, safety procedures, equipment setup, quality inspections and bonding methods. It also includes information related to megacast structures based on the organisation’s repairability studies and industry research.

Also read: Novelis aluminium hot mill plant in Oswego set to restart weeks ahead of schedule

The organisation said its 2025 research on megacasting repairability found that repairs can be cost-effective in some situations, but require specialised equipment, updated repair methods and technicians trained to handle aluminium structures correctly.

The programme also focuses on working safely with heat-sensitive materials and specialist welding systems used in aluminium vehicle repairs.

Graham Keep, who designed the course, said many technicians remain uncertain about repairing aluminium because of differences between aluminium and steel structures. In his words, “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.” 

For forward-thinking aluminium market insights amidst supply chain and price challenges, read "ALuminium LeaderSpeak 2026"

He further added, “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.” 

Dean Lander, head of repair sector services at Thatcham Research, said megacasting represents a major shift in vehicle design and engineering and noted that repairability planning would become increasingly important as the technology expands across the automotive industry.