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Are cast structural parts common on modern cars? I thought the structure of modern cars was forged parts welded together by robots.

Relatively new for such large parts, and an innovation by Tesla, although other manufacturers are picking the idea up too.

Doesn't that mean it's not cost effective to repair in case of accidents?

Small bump - got to dismantle the whole car and replace half of it.

So it's cheaper to build and they get to sell more cars?

I don't see why I should care about that as a potential car buyer.

Google "Gigapress."

Tesla pioneered cast frames as a way of dropping the cost to manufacture the car.