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Tesla’s aluminum alloys patent hints at ultra-tough EVs that are cheaper to produce
It is widely known that Tesla constantly innovates, from the software of its cars to the chemistry of the batteries that power them. And if a newly published patent application is any indication, it appears that Tesla’s innovations actually go all the way down to the metals used to build its cars. By using aluminum alloys that were developed by the company, for example, Tesla may be able to usher in a new breed of electric cars that are incredibly tough while being cheaper to produce.
The patent, titled “Die Cast Aluminum Alloys for Structural Components,” describes an aluminum alloy that is both extremely tough and ductile. The aluminum alloy would not require further processing as well, allowing the company to improve its production costs.
In the patent’s description, Tesla noted that commercial cast aluminum alloys such as those used for electric vehicle chassis need to be both strong and ductile. Aluminum alloy components are typically formed by casting. If produced well, casted parts could be produced quickly and reliably, and they should maintain their structural properties well. Alloys that cannot be casted well, however, result in hot tearing, which causes issues.
Tesla emphasized that numerous structural components made of aluminum alloys today may require processes like heat treating, which improves strength, hardness, ductility, and corrosion resistance. These processes ensure quality, but they also require large capital expenditures, extended processing times, and potential yield losses. With this in mind, Tesla noted that it would be preferable to produce aluminum alloys with high yield strengths and sufficient ductility, while requiring no heat treatment.
Tesla describes some of its ideas in the following section.
“In one embodiment, the alloy comprises a yield strength of at least about 130 MPa and a bend angle of at least about 20° at a 3 mm section thickness when as-cast and without further processing. In one embodiment, the aluminum alloys comprise vanadium to provide many of these enhancements. In another embodiment, the aluminum alloy has a specific weight ratio of copper to magnesium to provide many of these enhancements of an alloy with the desired features. In one embodiment, the aluminum alloy has a weight ratio of Cu:Mg of about 4:1 to about 1: 1. In one embodiment, the aluminum alloy has a weight ratio of Cu:Mg of about 4: 1 to about 2: 1.
“As mentioned below, aluminum alloys with these compositions were found to have high yield strength and high ductility compared to available aluminum alloys. As mentioned below, the aluminum alloys are described herein by the weight percent (wt %) of the total elements and particles within the alloy, as well as specific properties of the alloys, it will be understood that the remaining composition of any alloy described herein is aluminum and incidental impurities.”
If Tesla could effectively introduce novel aluminum alloys for its vehicles, the company would likely be able to improve its production costs and its products’ overall quality. Stronger aluminum alloy parts may pave the way for vehicles that are safer than ever before, while the lack of heat treatment could ensure that Tesla’s operating costs are optimized further. The aluminum alloy parts may also contribute to higher production outputs, especially if they are fully compatible with the company’s megacast strategies.
Read Tesla’s full patent below.
Tesla Die Cast Aluminum Alloy Patent by Simon Alvarez on Scribd
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Tesla Model Y L becomes China’s 4th best-selling mid-to-large SUV in its first month of sales
Tesla Model Y L was able to sell 8,221 units domestically in September.

The Tesla Model Y L has only started deliveries last month, but it is already making its presence known in China’s mid-to-large SUV segment. As per data aggregated by Tesla watchers in China, the Model Y L has quickly risen as one of the country’s best-selling large SUVs just weeks into its first deliveries.
The momentum of the Model Y L has been so notable that it ended up being China’s fourth best-selling mid-to-large SUV in September.
Tesla Model Y L September sales
As per data compiled by Yiche, the Tesla Model Y L was able to sell 8,221 units domestically in September. This places it in fourth place in China’s rankings for best-selling large SUVs, just below the Leapmotor C16, the Li Auto L6, and the Xiaomi YU7, which sold 8,312, 11,827, and 22,244 units in September, respectively.
A look at the prices of China’s top four mid-to-large SUVs would show that the Model Y L is one of the pricier vehicles among the four. The Xiaomi YU7’s inclusion in the list is also quite interesting as the all-electric crossover primarily competes with the five-seat Model Y, not the Model Y L. Needless to say, the price difference between the Model Y L and the Xiaomi YU7 is quite substantial.
Just getting started
The Tesla Model Y L only started deliveries sometime in September. Following its launch in August, the Model Y L received positive reviews from professional reviewers, with many praising the vehicle’s spacious cabin and its reasonable price. It did not take long before the Model Y L was sold out for October, and later, November as well. Considering that the Model Y L now has an estimated delivery date of December 2025 for new orders, it seems safe to assume that every unit built by Giga Shanghai this quarter will be sold to consumers.
The Model Y L has the makings of a best-seller. With a spacious second row that features two captain seats with retractable armrests, as well as a third row that could accommodate regular-sized adults, the Model Y L is a true family hauler. Combined with its starting price of $47,566 before options, the extended wheelbase all-electric crossover SUV does seem to have the makings of a best-seller.
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Tesla makes a change to its ‘American Heroes’ $500 discount

Tesla has made a change to its “American Heroes” discount, which takes $500 off the price of a vehicle purchase if you work in a certain field.
Tesla first launched the American Heroes discount earlier this year on May 22, 2025, and it initially started as a $1,000 deduction on the price of any of the company’s vehicles.
It formerly allowed military veterans, retirees, active-duty members, their spouses, first responders, teachers, and students. It utilized ID.me to verify their occupation.
However, Tesla has added a few groups of workers to this discount, according to language on its website:
“Tesla vehicles are perfect for everyday American heroes. Offer available to verified military veterans, retirees, active-duty members, their spouses, surviving spouses, first responders, medical providers, nurses, students and teachers verified through ID.me1. Adjustments applied when you place your order after verification. Eligibility criteria detailed at ID.me.”
The discount applies to all five Tesla vehicles, so it is not restricted to just the S3XY lineup.
The American Heroes discount is one of the several offers and incentives that Tesla offers on its vehicles. Currently, it is one of four offers Tesla has on its vehicles, with the others being:
- Full Self-Driving (Supervised) Trial: Three-month trial for those who use a referral code to buy a vehicle.
- Premium Connectivity Trial: One-month free
- Financing Offers: Tesla has various financing offers, including a 3.99% APR with $5,000 on Model S and Model X orders in the U.S.
These incentives help drive sales, but they also show Tesla’s appreciation for those who work in challenging fields. The discount has no expiration, as of now, but with this recent addition, Tesla likely has no plans to eliminate the program.
Tesla has occasionally launched discounts for military members near the 4th of July as well.
News
Tesla might be doing away with a long-included feature with its vehicles
It appears Tesla is mulling the possibility of not including key cards with its vehicles any longer.

Tesla might be doing away with a long-included feature with its vehicles, as it could be looking to phase out something that very few owners utilize.
Tesla Key Cards are included when you purchase your vehicle, and they assist in the initial setup process. However, after that, they are not super useful or relevant to the owner, as many rely on their Phone Key through the Tesla App to access their cars.
As such, it appears Tesla is mulling the possibility of not including key cards with its vehicles any longer. According to some language that has been removed from vehicle Owner’s Manuals that talks about the inclusion of key cards with the car upon delivery:
“Tesla provides you with two Model 3/Y key cards, designed to fit in your wallet.”
That sentence was removed from Owner’s Manuals, according to Not a Tesla App, which first spotted the change.
Tesla Model 3 owner implants RFID key card chip into her arm as ultimate hack to unlock door
Interestingly, the timing of the phrase being removed from Owner’s Manuals comes just after Tesla launched its “affordable” Standard Models, and could be a small money-saving measure for the company.
Key Cards have been utilized by Tesla for its cars since 2017, as they became an included accessory with the vehicle. They still have their place and are useful for other applications, such as Valet service and even to be used by car owners if their phone is dead or if someone else needs to get into the car.
They can also be purchased in the Tesla Shop for $40.
It seems as if Tesla is planning to have owners be completely reliant on the Phone Key, which is more useful and convenient than carrying around the Key Cards.
Although it is minor, it is yet another strategy Tesla is using to trim any sort of costs that can be eliminated and could save money in the long run.
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