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
-->
Don’t hesitate to contact us with news tips. Just send a message to tips@teslarati.com to give us a heads up.
News
Tesla Model 3 named New Zealand’s best passenger car of 2025
Tesla flipped the switch on Full Self-Driving (Supervised) in September, turning every Model 3 and Model Y into New Zealand’s most advanced production car overnight.
The refreshed Tesla Model 3 has won the DRIVEN Car Guide AA Insurance NZ Car of the Year 2025 award in the Passenger Car category, beating all traditional and electric rivals.
Judges praised the all-electric sedan’s driving dynamics, value-packed EV tech, and the game-changing addition of Full Self-Driving (Supervised) that went live in New Zealand this September.
Why the Model 3 clinched the crown
DRIVEN admitted they were late to the “Highland” party because the updated sedan arrived in New Zealand as a 2024 model, just before the new Model Y stole the headlines. Yet two things forced a re-evaluation this year.
First, experiencing the new Model Y reminded testers how many big upgrades originated in the Model 3, such as the smoother ride, quieter cabin, ventilated seats, rear touchscreen, and stalk-less minimalist interior. Second, and far more importantly, Tesla flipped the switch on Full Self-Driving (Supervised) in September, turning every Model 3 and Model Y into New Zealand’s most advanced production car overnight.
FSD changes everything for Kiwi buyers
The publication called the entry-level rear-wheel-drive version “good to drive and represents a lot of EV technology for the money,” but highlighted that FSD elevates it into another league. “Make no mistake, despite the ‘Supervised’ bit in the name that requires you to remain ready to take control, it’s autonomous and very capable in some surprisingly tricky scenarios,” the review stated.
-->At NZ$11,400, FSD is far from cheap, but Tesla also offers FSD (Supervised) on a $159 monthly subscription, making the tech accessible without the full upfront investment. That’s a game-changer, as it allows users to access the company’s most advanced system without forking over a huge amount of money.
News
Tesla starts rolling out FSD V14.2.1 to AI4 vehicles including Cybertruck
FSD V14.2.1 was released just about a week after the initial FSD V14.2 update was rolled out.
It appears that the Tesla AI team burned the midnight oil, allowing them to release FSD V14.2.1 on Thanksgiving. The update has been reported by Tesla owners with AI4 vehicles, as well as Cybertruck owners.
For the Tesla AI team, at least, it appears that work really does not stop.
FSD V14.2.1
Initial posts about FSD V14.2.1 were shared by Tesla owners on social media platform X. As per the Tesla owners, V14.2.1 appears to be a point update that’s designed to polish the features and capacities that have been available in FSD V14. A look at the release notes for FSD V14.2.1, however, shows that an extra line has been added.
“Camera visibility can lead to increased attention monitoring sensitivity.”
Whether this could lead to more drivers being alerted to pay attention to the roads more remains to be seen. This would likely become evident as soon as the first batch of videos from Tesla owners who received V14.21 start sharing their first drive impressions of the update. Despite the update being released on Thanksgiving, it would not be surprising if first impressions videos of FSD V14.2.1 are shared today, just the same.
-->Rapid FSD releases
What is rather interesting and impressive is the fact that FSD V14.2.1 was released just about a week after the initial FSD V14.2 update was rolled out. This bodes well for Tesla’s FSD users, especially since CEO Elon Musk has stated in the past that the V14.2 series will be for “widespread use.”
FSD V14 has so far received numerous positive reviews from Tesla owners, with numerous drivers noting that the system now drives better than most human drivers because it is cautious, confident, and considerate at the same time. The only question now, really, is if the V14.2 series does make it to the company’s wide FSD fleet, which is still populated by numerous HW3 vehicles.
News
Waymo rider data hints that Tesla’s Cybercab strategy might be the smartest, after all
These observations all but validate Tesla’s controversial two-seat Cybercab strategy, which has caught a lot of criticism since it was unveiled last year.
Toyota Connected Europe designer Karim Dia Toubajie has highlighted a particular trend that became evident in Waymo’s Q3 2025 occupancy stats. As it turned out, 90% of the trips taken by the driverless taxis carried two or fewer passengers.
These observations all but validate Tesla’s controversial two-seat Cybercab strategy, which has caught a lot of criticism since it was unveiled last year.
Toyota designer observes a trend
Karim Dia Toubajie, Lead Product Designer (Sustainable Mobility) at Toyota Connected Europe, analyzed Waymo’s latest California Public Utilities Commission filings and posted the results on LinkedIn this week.
“90% of robotaxi trips have 2 or less passengers, so why are we using 5-seater vehicles?” Toubajie asked. He continued: “90% of trips have 2 or less people, 75% of trips have 1 or less people.” He accompanied his comments with a graphic showing Waymo’s occupancy rates, which showed 71% of trips having one passenger, 15% of trips having two passengers, 6% of trips having three passengers, 5% of trips having zero passengers, and only 3% of trips having four passengers.
The data excludes operational trips like depot runs or charging, though Toubajie pointed out that most of the time, Waymo’s massive self-driving taxis are really just transporting 1 or 2 people, at times even no passengers at all. “This means that most of the time, the vehicle being used significantly outweighs the needs of the trip,” the Toyota designer wrote in his post.
-->Cybercab suddenly looks perfectly sized
Toubajie gave a nod to Tesla’s approach. “The Tesla Cybercab announced in 2024, is a 2-seater robotaxi with a 50kWh battery but I still believe this is on the larger side of what’s required for most trips,” he wrote.
With Waymo’s own numbers now proving 90% of demand fits two seats or fewer, the wheel-less, lidar-free Cybercab now looks like the smartest play in the room. The Cybercab is designed to be easy to produce, with CEO Elon Musk commenting that its product line would resemble a consumer electronics factory more than an automotive plant. This means that the Cybercab could saturate the roads quickly once it is deployed.
While the Cybercab will likely take the lion’s share of Tesla’s ride-hailing passengers, the Model 3 sedan and Model Y crossover would be perfect for the remaining 9% of riders who require larger vehicles. This should be easy to implement for Tesla, as the Model Y and Model 3 are both mass-market vehicles.
Tesla Model 3 named New Zealand’s best passenger car of 2025
Tesla starts rolling out FSD V14.2.1 to AI4 vehicles including Cybertruck
