The Role of Spot Welding in Modern Vehicle Repairs

When most people think of collision repair, they picture welding torches, sparks flying, and metal being fused back together. But did you know that in many modern vehicle repairs, spot welding is the manufacturer’s required repair method? Today’s cars and trucks are built with materials and designs that depend on factory-level spot welds for strength, crash safety, and corrosion resistance.

At Solon Collision in Aurora, OH, we invest in OEM-approved equipment and training to perform these specialized welds exactly as the manufacturer specifies. Let’s break down why spot welding plays such an important role in auto body repair, where it’s used, and why choosing the right shop makes all the difference.

What Is Spot Welding?

Spot welding is a process that joins two pieces of sheet metal together by applying high electrical current through electrodes. Instead of melting filler wire (like traditional MIG welding), spot welding relies on resistance heat at the joint, fusing the metal together in a small “spot.”

This process is:

• Fast: Each weld takes just a fraction of a second.

• Strong: Proper spot welds match the strength of factory welds.

• Clean: No filler metal or grinding is needed.

It’s the same process used at the factory when your vehicle was first built, which is why automakers require shops to replicate it after a collision.

Why OEMs Require Spot Welding

Modern vehicles are designed and crash-tested with spot welds in specific locations. Changing that repair method could alter the way a vehicle reacts in a crash, compromising passenger safety.

Here’s why OEMs specify spot welding:

• Crash Integrity: Spot welds provide consistent strength and energy absorption during a collision.

• Heat Control: Unlike MIG welding, spot welds minimize the heat-affected zone (HAZ), preventing damage to high-strength steels.

• Corrosion Resistance: Spot welds preserve protective coatings like galvanizing, reducing the risk of rust.

• Factory Match: Repairs maintain the original look and function of the vehicle.

Where Is Spot Welding Used in Repairs?

Spot welding is especially important in areas where multiple layers of sheet metal overlap. Common locations include:

• Rocker panels

• Quarter panels

• Roof skins

• Door frames

• Trunk panels

If your vehicle needs one of these parts replaced after an accident, there’s a good chance OEM procedures call for spot welding rather than plug welding or MIG welding.

The Tools and Training Behind Spot Welding

Not every body shop can perform spot welding correctly. OEM-approved spot welders cost tens of thousands of dollars and require specialized training to use properly.

At Solon Collision, our team is trained in:

• I-CAR Gold Class procedures

• OEM repair manuals and position statements

• Proper machine settings for different steels

This ensures every weld we perform is not just strong — it’s identical to the way the factory built your vehicle.

Spot Welding vs. Plug Welding: What’s the Difference?

For years, many shops used plug welds (a small hole filled with a MIG weld) as a substitute for factory spot welds. While it was common practice on older cars, it’s not acceptable on many modern vehicles.

That’s because:

• Plug welds create larger heat-affected zones.

• Plug welds may not provide the same strength in high-strength steels.

• OEM crash tests are based on spot welds, not substitutes.

This is why following OEM procedures is non-negotiable. At Solon Collision, if the repair calls for spot welds, that’s exactly what we do.

Why Choosing the Right Shop Matters

Your vehicle’s safety depends on correct welding methods. Unfortunately, not every shop invests in the right tools or follows OEM guidelines. If spot welds are skipped or replaced with improper welds, it could:

• Reduce crash performance

• Void manufacturer warranties

• Lower your vehicle’s resale value

• Lead to premature rust or failure

At Solon Collision, we don’t cut corners. We invest in the right equipment, training, and procedures so your repair is done once and done right.

FAQs About Spot Welding in Auto Body Repair

Is spot welding stronger than MIG welding?

• In structural areas where OEMs require it, yes. Spot welding produces consistent results that match factory standards.

Can any shop perform spot welding?

• No. Only shops with OEM-approved equipment and trained technicians should attempt it.

Why is spot welding more expensive?

• It’s not always more expensive — but the investment in equipment and training is significant. The cost is about ensuring safety, not cutting corners.

Final Thoughts

Spot welding isn’t just a “technical detail” — it’s a critical repair method that ensures your vehicle is safe, strong, and built to last after a collision. By choosing a shop that follows OEM-approved welding processes, you protect your investment and your family’s safety.

At Solon Collision in Aurora, OH, we perform every repair the right way, using spot welding where required by the manufacturer. Trust us to bring your car back to factory condition with precision and care.

📞 Call us today at 440-903-1009 or visit us at 260 Lena Drive, Aurora, OH 44202 to schedule your repair.