Complexity is the enemy of affordability, and cars have an affordability problem. An automobile has always been a big investment, but now, more than ever, the problems come once the car leaves the dealer’s lot. While an out-of-warranty repair or a minor collision was once somewhat affordable to fix, even the simplest-seeming parts of a car can cost thousands of dollars. A new bumper, for example, is no longer something simple and relatively inexpensive to replace.
Cars Have Become Rolling Computers
2026 Mercedes-Benz CLA-Class fully-funtional dashboard with all three display screensMercedes-Benz
Cars becoming rolling computers isn’t a new complaint, but we’re not talking about a fairly basic ECU chip or sensors for the engine and brakes anymore. We’re referring to full computer systems that pull data from all around the car, and this tech controls the vehicle based on that input. Even fairly basic driver-aid systems like adaptive cruise control and blind-spot monitoring can require cameras, radar, and even lidar (consisting of laser imaging, detection, and ranging).
To create a package of advanced driver-assistance systems (ADAS) or safety systems that includes adaptive cruise control, automatic emergency braking, blind-spot monitoring, lane-keep assistance, and so on, the sensors require dozens of electronic control modules to process and respond to inputs. Add torque control to the electronic stability control (ESC) system, and that’s a lot of processing and sensors working together.
That’s mixing in software and hardware, and it just increases with a sophisticated all-wheel-drive system. There are huge expansions in software integration happening. For example, many modern infotainment systems can display data from the vehicle’s other computers while also requiring their own hardware, such as a screen and possibly buttons.
Small Damage Can Mean Big Repairs
BMW Mistral AI Crash SimulationBMW
The complexity of computer systems means many things can fail and require repair. But a small impact can cause expensive damage. Parking sensors in a bumper will need to be repaired and calibrated or recalibrated if reused. New sensors cost between $100 and $300 each, while lidar and radar units for adaptive cruise control and automatic emergency braking can run from $900 to $2,000 each.
Radar and lidar units aren’t in the bumper so much anymore, but in a heavy crunch, a front grille can be shockingly expensive to replace. A luxury car can now contain four cameras and six sensors in a single bumper. Calibrating sensors is a complex process that requires specialized equipment costing shops tens of thousands of dollars. The calibration takes one to two hours and requires specific procedures for each make and model.
Even a cracked bumper isn’t necessarily easy to repair now, as it often requires specialized materials and repair and paint techniques. A crack near a mounting point typically means replacing the whole thing, and welding isn’t often a viable option anymore.
Safety Is Expensive
Steering its way to safety. The Lane Keep Assist technology can save lives, but it can also be extremely intrusive in the driving experience.NCAP
A car’s bumper is also a piece of technology now, not to mention the sensors. There’s a reinforcement bar behind the cover with specific crush characteristics to work with the vehicle’s crumple zones. Crash safety has evolved to the point where it’s carefully engineered to absorb impact without transmitting it to the passenger area. The result is brilliant for crash safety, but the car is designed to crumple as a whole from the front and back in a collision.
There have also been tales of accidents that cause minor damage but still set off airbags, leading to a car being written off by an insurance company. There’s a truth in that because airbags are expensive to replace, there is a lot in even the most affordable new cars now.
Safety Drove The Change
Insurance Institute for Highway Safety. IIHS. 2026MY Jeep Wrangler four-door. Crash test dummyInsurance Institute for Highway Safety (IIHS)
Nearly everything we are mentioning involves a safety improvement in cars, and the results are positive. From 1979 to 2005, the number of deaths on the road per year decreased by 15%, and that’s as the number of cars on the road increased. According to the National Highway Traffic Safety Administration (NHTSA), there were 36,640 traffic fatalities in 2025 – a 6.7% decrease from 2024.
Reducing traffic deaths isn’t the whole story, but the reduction in injury due to crash protection is hard to quantify. But,
It’s safe to say that airbags, side-impact protection, and massive advances in understanding energy dissipation reduce injuries or prevent worse injuries from impacts. While the sensors and computers are there to prevent impacts, the physical safety systems are there for when they’re unavoidable.
We have reached the point where the development of safety systems is so advanced that it has enabled groups like the Insurance Institute for Highway Safety to shift some of their focus to bigger-picture safety issues. Everything from seatbelt reminders to adding electronic safety systems, but the new frontier really is accident prevention. Unfortunately, much of that is outside automakers’ control – things like driver education and road layout.
The Future Of Vehicle Repairs
A mechanic works under the hood of a Ford F-150Ford
While it’s excellent news that technology is helping avoid crashes and literally reducing the impact of accidents when they happen, it’s getting incredibly expensive to do so. The situation is a blessing and a challenge, as greater complexity leads to expensive parts and specialized technician training for repairs that must be justified on cost grounds. Insurance companies also have to consider all of these factors before charging us premiums and making a profit.
If safety systems pay for themselves by reducing costly accidents, that would be a win. Some cars now have their lidar sensors on the roof, which moves them out of harm’s way to the point that if one gets damaged, there are far bigger things to worry about.
General sensors should, in theory, become less expensive over time, but that can’t be until deep into the development cycle, when there are few gains to be made or a single sensor can do the job of several at a lower cost. Standardization and modularity across systems and software can help, with systems that automatically calibrate themselves. The reality is, though, that all of this isn’t mature technology yet, particularly the software systems that were promised to make life easier and less expensive through over-the-air updates.
It Doesn’t Have To Be This Way
2027 Slate Truck side angle in gray while parked under a sign with its starting priceIan Wright/CarBuzz/Valnet
When it comes to repairing vehicles, much depends on how the vehicle is designed and built. The upcoming Slate truck is an example of a new automaker potentially making a vehicle simple enough that anyone with a few tools can fix it. A great example is the body panels on the Slate Truck, which are easy to unbolt and replace. In addition, the vehicles are designed to be easily vinyl-wrapped rather than painted.
There are also obvious things legacy automakers can do, like not put big 20-inch or larger alloy wheels on affordable cars. Something as simple as replacing a tire gets more expensive the larger the tire, and a damaged wheel even more so. The issue there, of course, is that a larger wheel is more attractive to many car buyers, whether it’s a performance car or not. However, a lot of the time there isn’t an option for more reasonably sized wheels and tires.
Ultimately, it will come down to automakers taking repair costs into account. However, replacement parts and repairs are income for an automaker and dealerships. The dice will likely remain loaded unless an automaker like Slate changes the paradigm of what’s considered affordable.
Sources: IIHS / NHTSA / Kelly Blue Book / USA Today / AutoBlog
