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Tesla patents ‘fibrous foam architecture’, hinting at new seating material and interior trim to come

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Tesla has submitted a patent application for a “fibrous foam architecture” with claims that the manufacturing technique for seats and interior trim would create a more efficient and environmentally-sustainable process.

The submitted patent explains that the current materials used for cushioning in traditional vehicle seats include foam made from polyurethane, a material that is not able to be recycled and may not be the most comfortable due to its lack of breathability. Manufacturing the foam is also a time-consuming and laborious process that involves the pouring and mixing of numerous chemicals, like polymer or epoxy, into a mold. After setting, this requires additional material to be trimmed and shaped, thereby creating unnecessary waste that Tesla’s fibrous foam architecture hopes to eliminate.

The background of the patent states, “Trim to foam assembly may include hog ring, hook and loop, and/or clipping methods. In such methods, alignment tolerances may need to be maintained, mating surface limitations may need to be met, trenches and stitches may need to be provided and so on. Glue application storage and handling may also be required. Current manufacturing processes may be labor-intensive and time-consuming.” This would improve the production and quality of backrests, armrests, leg-rests, and bolsters.

Tesla is looking to improve upon its vehicle’s interior, as it suggests “there is a need for an improved foam architecture and associated manufacturing process that overcome the aforementioned drawbacks.”

An improved foam structure for vehicle seating will provide a new, more comfortable, recyclable material for owners of Tesla electric cars. Tesla plans to use the stacking of multiple layers of different materials to make a less-laborious and more cost-effective seating option. The use of sustainable materials that can be recycled after use will appeal to the environmentally-conscious Tesla owner. The company unveiled 100% cruelty-free seat options in 2017 to its Model S and Model X, and would later offer the 100% vegan material for the Model 3 and the upcoming Model Y.

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Tesla has continued to improve its vehicles in every way imaginable for its customers through OTA power updates and accessibility features while finding efficiencies in its design and manufacturing process to support a wider scale-out in production. The company is gearing up for the initial production of the Model Y in early 2020 and the first mass-production of the Model 3 from its Shanghai-based Gigafactory 3. Tesla announced during the Q3 earnings call, “trial production of Model 3 in Shanghai has begun, ahead of schedule. We are also ahead of schedule to produce Model Y and now expect to launch by summer 2020. Model Y equipment installation is underway in advance of the planned launch next year. We are moving faster than initially planned, using learnings and efficiencies gained from our Gigafactory Shanghai factory design.”

As Tesla begins to increase the rate of production of its fleet of vehicles, efficiency is a key factor in creating a lean and cost-effective manufacturing process. Tesla is set to begin production of the Model Y crossover in 2020 and will unveil its highly-anticipated Cybertruck on November 21

The full details of Tesla’s patent application for a “Fibrous Foam Architecture” can be viewed here.

Joey has been a journalist covering electric mobility at TESLARATI since August 2019. In his spare time, Joey is playing golf, watching MMA, or cheering on any of his favorite sports teams, including the Baltimore Ravens and Orioles, Miami Heat, Washington Capitals, and Penn State Nittany Lions. You can get in touch with joey at joey@teslarati.com. He is also on X @KlenderJoey. If you're looking for great Tesla accessories, check out shop.teslarati.com

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Elon Musk

Elon Musk shares unbelievable Starship Flight 10 landing feat

Flight 10’s Starship upper stage demonstrated impressive accuracy when it came to its target landing zone.

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Credit: SpaceX/X

SpaceX CEO Elon Musk recently shared an insane feat accomplished by Starship’s upper stage during its tenth test flight.

Despite the challenges it faced during its return trip to Earth, Flight 10’s Starship upper stage demonstrated impressive accuracy when it came to its target landing zone.

Against the odds

Musk’s update was shared on social media platform X. In a conversation about Starship upper stage’s return to Earth, Musk revealed that the upper stage splashed down just 3 meters (under 10 feet) from its intended target. Considering the size of the Starship upper stage and the ocean itself, achieving this accuracy was nothing short of insane.

Starship Flight 10 was a success as both the Super Heavy booster and Ship upper stage completed all their mission objectives. However, videos and images released by SpaceX showed the upper stage’s heat shield scorched golden-brown and parts of its aft skirt visibly missing. The flaps and other surfaces also bore signs of heavy stress from reentry.

SpaceX highlighted this in a post on X: “Starship made it through reentry with intentionally missing tiles, completed maneuvers to intentionally stress its flaps, had visible damage to its aft skirt and flaps, and still executed a flip and landing burn that placed it approximately 3 meters from its targeted splashdown point,” SpaceX noted.

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A key milestone

The result stands in stark contrast to Starship’s earlier test flights this year, when all three prior upper-stage flights in 2025 ended in premature breakup before splashdown. Flight 10 not only marked the first successful splashdown of the year for the Starship upper stage, but it also delivered near-perfect precision despite its battered state, according to a Space.com report.

For SpaceX, this success is a critical proof point in developing a fully reusable launch system. A spacecraft capable of surviving severe reentry conditions and still landing within meters of its target underscores the robustness needed for future missions, including orbital payload deliveries and, eventually, landings on the Moon and Mars.

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New Tesla Model Y Performance launches from Giga Berlin

The vehicle is produced at Gigafactory Berlin and is available to order now in Europe and the Middle East.

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Credit: Tesla

It took some time, but the new Tesla Model Y Performance is finally here. The new Model Y Performance features a blend of aerodynamic improvements, upgraded interior comforts, and high range enabled by new battery cells. 

The updated Model Y Performance is produced at Gigafactory Berlin and is available to order now in Europe and the Middle East. First deliveries are expected in 1-2 months.

Key Model Y Improvements

The new Model Y Performance sharpens the vehicle’s design and driving dynamics while adding subtle interior refinements. The revised variant now delivers 0–60 mph in 3.3 seconds, slightly quicker than its predecessor’s 3.5 seconds, while offering an EPA-estimated 308 miles of range, just about 1% less than the non-performance Dual Motor All Wheel Drive variant. Top speed is listed at 155 mph.

The exterior of the new Model Y Performance features new front and rear fascias, along with a carbon fiber spoiler designed for greater downforce and reduced drag. Staggered wheels and tires provide improved steering precision and grip, while high-performance brakes offer enhanced pedal feel and better heat management. The ride is supported by adaptive suspension that adjusts damping based on road conditions, paired with unique drive modes tailored for high-speed performance. Ground clearance is listed at 6.1 inches, and weight is listed at 2,033 kilograms (4,482 pounds).

Tech and Interior

Inside, Tesla has added carbon fiber decor, expanded ambient lighting in the footwells and door pockets, and upgraded seating. The first-row sport seats now include power recline, power tilt, heating, ventilation, and powered thigh extensions for added support during cornering. Rear passengers receive perforated heated seats with power recline. A new 16-inch QHD center touchscreen anchors the cabin’s technology suite.

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Additional upgrades include eight exterior cameras, with the refreshed design introducing a new forward-facing unit. The high-density battery pack also boosts charge capacity but also helps maintain range despite the Performance model’s added power output.

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Elon Musk reveals when SpaceX will perform first-ever Starship catch

“Starship catch is probably flight 13 to 15, depending on how well V3 flights go,” Musk said.

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Credit: SpaceX

Elon Musk revealed when SpaceX would perform the first-ever catch attempt of Starship, its massive rocket that will one day take life to other planets.

On Tuesday, Starship aced its tenth test flight as SpaceX was able to complete each of its mission objectives, including a splashdown of the Super Heavy Booster in the Gulf, the deployment of eight Starlink simulators, and another splashdown of the ship in the Indian Ocean.

It was the first launch that featured a payload deployment:

SpaceX Starship Flight 10 was so successful, it’s breaking the anti-Musk narrative

SpaceX was transparent that it would not attempt to catch the Super Heavy Booster, something it has done on three previous occasions: Flight 5 on October 13, 2024, Flight 7 on January 16, and Flight 8 on March 6.

This time, it was not attempting to do so. However, there are bigger plans for the future, and Musk detailed them in a recent post on X, where he discussed SpaceX’s plans to catch Starship, which would be a monumental accomplishment.

Musk said the most likely opportunities for SpaceX to catch Starship itself would be Flight 13, Flight 14, and Flight 15, but it depends on “how well the V3 flights go.”

The Starship launched with Flight 10 was a V2, which is the same size as the subsequent V3 rocket but has a smaller payload-to-orbit rating and is less powerful in terms of initial thrust and booster thrust. Musk said there is only one more V2 rocket left to launch.

V3 will be the version flown through 2026, as V4, which will be the most capable Starship build SpaceX manufactures, is likely to be the first company ship to carry humans to space.

Musk said that SpaceX planned to “hopefully” attempt a catch of Starship in 2025. However, it appears that this will likely be pushed back to 2026 due to timing.

SpaceX will take Starship catch one step further very soon, Elon Musk confirms

SpaceX would need to launch the 11th and 12th test flights by the end of the year in order to get to Musk’s expected first catch attempt of Flight 13. It’s not unheard of, but the company will need to accelerate its launch rate as it has only had three test flights this year.

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