If it is possible to cast in aluminum the entire vehicle body, its obvious Tesla will do it in 1 piece or 2. Don't have to do the roof (its glass) or doors, hood or trunk. Remember how much of the dicast hot wheels bodies are cast- whole thing. Think scale is an issue? Entire class 8 truck frames have been cast. Achieving this, assuming paintable smoothness (think hot wheels) is a massive cost saver and reduces weight. It can still be repaired but don't even start with that as Monro has said you go solid state reliable and cost effiency or modular- not both!
The more I think on it the more I think Tesla's will become almost 100% cast aluminum, even the structual component battery enclosure. The doors, hood and truck can be cast too as a single piece and separated. You see this in plastic model sets.
A vehicle body consists of thin panels and thicker structural members. To comply with crashworthiness requirements, the frame itself must deform and absorb energy in a controlled manner. It is not possible to cast thin uniform body panels. They are typically made from rolled aluminum or steel. There is also the issue of cost and quality. The larger the casting, the more likely there will be defects. Any serious defect will either render the casting unusable or require a custom repair. Ford, by the extensive use of aluminum in the F-150 series trucks, appears to be the industry leader in the use of aluminum in mass produced vehicles, not Tesla.
The only cars with die cast bodies are the toy ones. As @DaleL says there is a cost, quality and most importantly safety factor. Many cars have a crumple zone to protect occupants. A die cast body will not provide the safety factor. You have to remember most crashes are head on, not to many are sideways https://en.wikipedia.org/wiki/Crumple_zone#/media/File:Cross_section_of_Saab_9000.jpg Cross section to show the different strength of the metal in a Saab 9000. The safety cell is in stronger metal (red) compared to the crumple zones (yellow). Of course, the exoskelton of the cybertruck may be rigid, hence not sure how the crumple zones will be designed. But even there I cannot see a die case body. A class 8 frame is a different being. It needs shearing/compression strength to carry loads, Any impact will be minimum on the cab. So even if the frame is die cast, the cab is not. bodybuilder.navistar.com/General/Documents/Saleinfo/CT471dates/20140228/CT471/Series/DuraStar/Durastar_frames.pdf
It is most likely there will be a forward cast; a structural battery, and a rear casting. A single dent totaling the car is unlikely as the casted parts bolt to the next section. The Model 3 is designed with considerable crush distances even today. There would expen$ive labor cost removing parts and the wiring and tubing needed. These repair expenses would easily exceed the cost of a replacement car; decrease safety, and; result in a salvage title. There is a reason why many of us carry insurance. Bob Wilson
Even today, many brackets, covers, casings etc. are cast and so are most of the ICE parts. So yes, I can see the battery housing, and and many of the smaller parts being cast. The OP's premise was that the body would be cast, which would not make economic or technical sense (if safety is also considered a technical issue).
