What is your car made of? If you answer, “A lot of things,” you’re correct. It’s a surprisingly difficult question to answer. Do you mean material by volume? Material by surface area? Or should the answer be the most important material? If we narrow the question to the body of the vehicle, the frame that houses the engine, the driveshaft, the seats, and everything else—the answer is probably steel or aluminum.

Steel has been the go-to material for automakers for years, but aluminum is becoming increasingly popular. Estimates vary, but steel still comprises nearly three quarters of all vehicle body components in North America. However, aluminum’s share of that market has been steadily increasing. This poses the question: What does the increasing popularity of aluminum mean for auto body repair and, specifically, dent repair?

Aluminum panels and dent repair

When a vehicle suffers an impact, this often leaves dents in one or more panels. The panels are what comprise the body of a vehicle. All auto body repair technicians working today have experience working with steel for dent repair, because of the metal’s dominance of the automotive market. But now that aluminum comprises roughly a quarter of all vehicle bodies, collision repair technicians are having to refine their processes.

How dent repair works?

The exact process of a dent repair depends on the type of dent, the type of vehicle, and, as we’ll see, the material involved. The basic process typically begins with an evaluation of the damage. With careful assessment, auto body repair technicians can figure out the best method of repair based on the dent’s size, depth, and location.

For minor, shallow dents that leave the automotive paint intact, collision repair technicians often use a paintless dent repair (PDR) method. PDR involves carefully massaging the metal back into shape from behind the panel using specialized tools. For more severe dents and dings that have damaged the paint, or more intensive dent repair is necessary.

This kind of dent repair involves sanding down the area, filling it with body filler, and then sanding it smooth before repainting and clear-coating the surface to match the original finish. A collision repair shop with automotive paint matching capabilities is crucial for this, or you might end up with a discoloration where the dent was. In some cases, especially with larger or creased dents, panel replacement might be necessary. When done right, dent repair restores the vehicle’s appearance and maintains its structural integrity.

So, is dent repair possible on an aluminum panel?

Yes, collision repair shops can perform dent repair on aluminum bodies. However, if you own a vehicle with an aluminum body, you must find an auto body repair shop that has the tools and know-how to repair an aluminum panel.

This means finding an auto body repair business that has special equipment to work on aluminum bodies. Using the same tools for both materials can damage panels. For example, steel shavings from other cars can affect an aluminum panel. Dent repair on aluminum panels differs from steel because aluminum is lighter, more rigid, and doesn’t have the same “memory” as steel. Steel is remarkably good at returning to its original shape with a little massaging. Aluminum doesn’t have the same attribute.

A paintless dent repair on an aluminum panel requires more precision and often more force, with collision repair technicians using specially designed tools. Another factor to consider is that aluminum conducts heat differently. During dent repair, the technicians apply heat to make the metal panel more pliable. But with an aluminum panel, this process requires great care and just the right temperature, as aluminum is much less forgiving of mistakes than steel.

Aluminum also reacts differently to body fillers and adhesives, and collision repair techs can’t reshape it as easily through traditional hammer-and-dolly techniques. As a result, aluminum dent repairs, even paintless dent repairs, often take longer and may require certified technicians trained specifically in aluminum repair methods. If there are deep or sharp dents, a full panel replacement is likelier than it is with a steel panel.

Advantages of aluminum panels

Clearly, aluminum dent repair is trickier. So why would you want an aluminum auto body? Well, the main reason is weight. Because aluminum is lighter, vehicles with an aluminum body can get better fuel economy. Aluminum also has a terrific strength-to-weight ratio. So, even though it’s noticeably lighter than steel, it’s not significantly weaker.

Aluminum panels are just as safe as steel panels. Aluminum’s ability to absorb impacts through deformation helps protect drivers and passengers. In fact, aluminum’s lightweight properties improve crash performance, because it reduces the overall weight of the vehicle, resulting in less momentum and a lower risk of severe impact forces.

Perhaps the biggest drawback of aluminum is its sensitivity to temperature. At very low temperatures, aluminum can become brittle and susceptible to damage. To counter this, automakers frequently use different aluminum alloys or reinforce certain areas of the vehicle’s body with steel.

Higher-end vehicles were the first to use aluminum on a large scale. Aluminum can be more expensive than steel, so it’s more common in brands such as Acura, Jaguar, BMW, and Mercedes-Benz. Now, even the Ford-150 has aluminum panels. Electric vehicles, such as Tesla, have also been big adopters of aluminum.