News
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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Elon Musk
SpaceX’s Starship V3 is almost ready and it will change space travel forever
SpaceX is targeting April for the debut test launch of Starship V3 “Version 3”
SpaceX is closing in on one of the most anticipated rocket launches in history, as the company readies for a planned April test launch and debut of its next-gen Starship V3 “Version 3”.
The latest iteration of Starship V3 has a slightly taller Super Heavy booster and Starship upper stage than their predecessors, and produce stronger, more efficient thrust using SpaceX’s upgraded Raptor 3 engines. V3 also features increased propellant capacity, targeting a total payload capacity of over 100 tons to low Earth orbit, compared to around 35 tons for its predecessor. With Musk’s lifelong aspiration to colonize Mars one day, the increased payload capacity matters enormously, because Mars missions require moving massive amounts of cargo, fuel, and eventually, people. But the most critical upgrade may be orbital refueling. SpaceX’s entire deep space architecture depends on moving large amounts of propellant in space, and having orbital refueling capabilities turn Starship from just a rocket into a true transport system. Without it, neither the Moon nor Mars is reachable at scale.
Initial Super Heavy V3 and Starbase Pad 2 activation campaign complete, wrapping up several days of testing that loaded cryogenic fuel and oxidizer on a V3 vehicle for the first time. While the 10-engine static fire ended early due to a ground-side issue, we saw successful… pic.twitter.com/uHGji17srv
— SpaceX (@SpaceX) March 18, 2026
A fully reusable Starship and Super Heavy, SpaceX aims to drive marginal launch costs down and at a tenfold reduction compared to current market leaders. To put that in perspective, getting a kilogram of cargo to orbit today costs thousands of dollars. Bring that number down far enough and space stops being an exclusive domain. That price point unlocks mass deployment of satellite constellations, large-scale science payloads, and affordable human transport beyond Earth orbit. It also means the Moon stops being a destination we visit and starts being one we inhabit.
NASA expects Starship to take off for the Moon’s South Pole in 2028, with the ultimate goal of establishing a permanently crewed science station there. A successful V3 flight this spring keeps that timeline alive. As for Mars, Musk has shifted focus toward building a self-sustaining city on the Moon first, arguing that the Moon can be reached every 10 days versus Mars’s 26-month alignment window. Mars remains the horizon, but the Moon is the proving ground.
Elon Musk hasn’t been shy with hyping the upcoming Starship V3 launch. In a social media post on Wednesday, he confirmed the first V3 flight is getting closer to launch. SpaceX also announced its initial activation campaign for V3 and Starbase Pad 2 was complete, wrapping up several days of cryogenic fuel testing on a V3 vehicle for the first time. The countdown is on. April can’t come soon enough.
Cybertruck
Tesla Cybertruck gets long-awaited safety feature
Tesla has announced the rollout of its innovative anti-dooring protection feature to the Cybertruck via the 2026.8 software update.
Tesla is rolling out a new and long-awaited feature to the Cybertruck all-electric pickup, and it is a safety addition geared toward pedestrian and cyclist safety, as well as accidents with other vehicles.
Tesla has announced the rollout of its innovative anti-dooring protection feature to the Cybertruck via the 2026.8 software update.
This safety enhancement uses the vehicle’s existing cameras to detect approaching cyclists, pedestrians, or vehicles in the blind spot while parked. Upon attempting to open a door, if a hazard is detected, the system activates: the blind spot indicator light flashes, an audible chime sounds, and the door will not open on the initial button press.
Drivers must wait briefly and press the button again to override, providing crucial seconds to avoid an accident.
Anti-dooring protection now rolling out to @Cybertruck
This feature comes standard on every new Model 3, Model Y & Cybertruck – using cameras to delay door opening if a cyclist, pedestrian or other vehicle is detected approaching in your blind spot
— Tesla North America (@tesla_na) March 17, 2026
The feature, also known as Blind Spot Warning While Parked, comes standard on every new Model 3 and Model Y, and is now extending to the Cybertruck. Leveraging Tesla’s vision-based system without requiring new hardware, it represents a cost-effective software solution that builds on community suggestions dating back to 2018.
This technology addresses the persistent danger of “dooring,” where a driver opens a car door into the path of a passing cyclist or pedestrian.
Tesla implemented this little-known feature to make its cars even safer
Dooring incidents are alarmingly common in urban environments.
According to Chicago data, in 2011 alone, there were 344 reported dooring crashes, accounting for approximately 20 percent of all bicycle crashes in the city, nearly one incident per day.
While numbers have fluctuated (dropping to 11 percent in 2014 before rising again), dooring consistently represents 10-20 percent of bike-related crashes in major cities.
A national analysis of emergency department data estimates over 17,000 dooring-related injuries treated in the U.S. over a decade, with many involving fractures, contusions, and head trauma, particularly affecting upper extremities.
By automatically intervening, Tesla’s system not only protects vulnerable road users but also safeguards its owners from potential liability and enhances overall road safety.
As cities promote cycling for sustainable transport, features like this demonstrate how advanced driver assistance and camera systems can evolve beyond highway driving to everyday urban scenarios.
Enthusiastic responses on social media highlight appreciation for the proactive safety measure, with some calling for broader rollout to older models where hardware permits. Tesla continues to push the boundaries of vehicle safety through over-the-air updates, making its fleet smarter and safer over time.
Elon Musk
Tesla Roadster is ‘sorcery and magic’ and might be worth the wait, Uber founder says
Perhaps the wait will be worth it, especially according to Uber founder Travis Kalanick, who recently teased the Roadster’s potential capabilities based on what he has heard from internal Tesla sources.
Tesla is planning to unveil the Roadster in late April after years of waiting. But the wait might be worth it, according to Travis Kalanick, the founder of Uber, who recently shed some light on his expectations for the all-electric supercar.
We all know the Roadster is supposed to have some serious capability. CEO Elon Musk has said on numerous occasions that the Roadster will be unlike anything else ever produced. It might go from 0-60 MPH in about a second, it might hover, it might have SpaceX cold gas thrusters.
However, the constant delays in the Roadster program and its unveiling event continue to send Tesla fans into confusion because they’re just not sure when, or if, they’ll ever see the finished product.
Perhaps the wait will be worth it, especially according to Uber founder Travis Kalanick, who recently teased the Roadster’s potential capabilities based on what he has heard from internal Tesla sources.
Kalanick said on X:
When I’ve run into people who are in the know, I inquire, they tell me nothing, but their eyebrows raise and their eyes widen in a way that can only mean something of sorcery and magic is coming…
— travis kalanick (@travisk) March 17, 2026
Musk has said this vehicle is not going to be geared for safety, and that, “If safety is your number one goal, do not buy the Roadster.”
There has been so much hype regarding the Roadster that it is hard to believe the company could not come through on some kind of crazy features for the vehicle.
However, the latest delay that Tesla put on the unveiling event is definitely eye-opening, especially considering it is the latest in a series of pushbacks the company has put on the vehicle for the past several years.
Tesla has made several jumps in the Roadster project over the past few months, as it has ramped up hiring for the vehicle and also applied for a patent for a new seat design.
The car has been a back-burner project for Tesla, as it has been focusing primarily on autonomy and the rollout of Robotaxi and Cybercab. Additionally, its other vehicle projects, like the Model 3 and Model Y refreshes, took precedence.
Tesla still plans to unveil the Roadster next month, so we can hope the company can stick to this timeframe.