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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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Elon Musk
How much of SpaceX will Elon Musk own after IPO will surprise you
SpaceX’s IPO filing confirms Musk will maintain his voting power to make key decisions for the company.
Elon Musk will retain dominant voting control of SpaceX after it goes public, according to the company’s IPO prospectus that was filed with the SEC. The filing reveals a dual-class equity structure giving Class B shareholders 10 votes each, concentrating power with Musk and a handful of other insiders, while Class A shares sold to public investors carry one vote.
Musk holds approximately 42% of SpaceX’s equity and controls roughly 79% of its votes through super-voting shares. He will simultaneously serve as CEO, CTO, and chairman of the nine-member board after the listing. Beyond that, the filing includes provisions that may limit shareholders’ influence over board elections and legal actions, forcing disputes into arbitration and restricting where they can be brought.
The case for Musk holding this level of control is grounded in SpaceX’s actual history. The company’s most important bets, from reusable rockets to a global satellite internet constellation, were decisions that ran against conventional aerospace thinking and would likely have faced resistance from a board accountable to investor gains. Fully reusable rockets were considered economically irrational by established industry players for years. Starlink, which now generates over $4 billion in annual operating profit, was widely dismissed as financially unviable when it was proposed. The argument for concentrated founder control seems straightforward, and the decisions that built SpaceX into what it is today required someone willing to ignore consensus and absorb years of losses.
SpaceX files confidentially for IPO that will rewrite the record books
For context, Musk’s position is significantly more dominant than Zuckerberg’s at Meta. The comparison with Tesla is also worth noting. When Tesla did its IPO in 2010, it did not issue dual-class shares. Musk has only recently pushed for enhanced voting protection, proposing at least 25% control at Tesla in 2024 after selling shares to fund his Twitter acquisition left him with around 13%.
SpaceX has clearly learned from that experience and structured the IPO differently by planning to allocate up to 30% of shares to retail investors, roughly three times the typical norm for a large offering. The roadshow is expected to begin the week of June 8, with a Nasdaq listing rumored to be a $1.75 trillion valuation and a $75 billion raise.
News
Tesla bolsters App with new safety, insurance, and storage features
The Tesla Smartphone App is one of the biggest and best features and advantages owners have. Everything from moving the vehicle with Summon, to getting Navigation sent to the car, to preconditioning the cabin can be done with the Tesla App.
Tesla is bolstering its smartphone App with a series of new features to streamline operations for owners. The new additions include fixes to safety, its in-house insurance offering, and storage management for Dashcam clips.
The Tesla Smartphone App is one of the biggest and best features and advantages owners have. Everything from moving the vehicle with Summon, to getting Navigation sent to the car, to preconditioning the cabin can be done with the Tesla App.
But in classic Tesla fashion, the company is aiming to improve the offerings of the app, and it is doing so with a handful of new features. They were first discovered by Tesla App Updates.
Tesla Insurance – Safety Score 3.0
This is truly part of the Spring 2026 Update, but Tesla has now given more transparency on how FSD has saved people money on their premiums.
Tesla intertwines FSD with in-house Insurance for attractive incentive
Additionally, Tesla is now automatically awarding a Safety Score of 100 for every mile traveled on Full Self-Driving (Supervised).
Update Tracking
Updates traditionally appear on the App or on the Center Touchscreen in the car. There is nothing better than seeing that Green Arrow at the top of the screen, or opening your app and seeing that there is a Software Update available.
Now, there will be no need to manually check the app and initiate the download. Tesla is enabling a new feature that will automatically download updates for you.
Storage Management
Your USB drive can now be remotely formatted, and old Dashcam clips can be deleted straight from the phone. When you record a lot of things using the Dashcam feature, that storage fills up pretty quickly.
Now, manually deleting the Dashcam videos is easier than ever.
Trailer Light Test
This is perhaps the coolest and most crucial addition to the Tesla App, as those who tow and haul will now be able to trigger a diagnostic light sequence from the app while standing behind your trailer to ensure the brake lights work.
Verifying your trailer lights are connected properly and operating normally and as intended is normally a massive hassle.
Now, a new trigger will be available to initiate a diagnostic light sequence directly from your phone.
News
Tesla is building private Superchargers just for Robotaxi
For Tesla, these Robotaxi-only Superchargers represent more than convenient parking spots. They are the first bricks in a vertically integrated autonomy platform—vehicles, energy, and software working in seamless concert.
Tesla is starting to build out Robotaxi-only Superchargers as the company is truly leaning on its Full Self-Driving and autonomy efforts to solve passenger travel.
Last week, the company filed pre-permits in Arizona’s East Valley for two dedicated, non-public charging sites stocked with next-generation V4 Superchargers. The filings mark the first visible evidence of purpose-built infrastructure exclusively for autonomous Tesla vehicles, as they state they are not for public use.
In Chandler, Tesla plans to install 56 V4 stalls on an industrial parcel along South Roosevelt Avenue. Site documents describe a high-capacity setup supported by new SRP transformers, switching cabinets, and upgrades to existing underground lines.
A second site in Mesa, located at 5349 E Main Street in another industrial zone, carries the same private-use designation. Both locations sit well away from public roads and customer traffic, ensuring the chargers serve only Tesla’s internal fleet.
The sites were spotted by Supercharger observer MarcoRP.
On the same day, Tesla also submitted a draft for another proposed location in the city of Mesa, also listed as private use.
This site is located in an industrial area on the east side of the city. pic.twitter.com/jCC1IsKKKw
— MarcoRP (@MarcoRPi1) April 17, 2026
Phoenix’s East Valley offers an ideal launchpad for Robotaxi Supercharging: the location has a clean, grid-like street layout and year-round mild weather that minimizes camera degradation. Additionally, Arizona has welcomed self-driving pilots since Waymo’s early days.
By securing private depots now, Tesla can optimize charging cycles, reduce downtime, and maintain full control over vehicle hygiene and security, critical factors for high-utilization Robotaxi operations.
The type of Supercharger is telling as well, as they are V4, Tesla’s fastest and most efficient buildout.
V4 stalls deliver faster power and support bidirectional charging, features that will let idle Robotaxis feed energy back to the grid during off-peak hours. Because the sites are closed to the public, Tesla avoids congestion, vandalism risks, and the scheduling conflicts that plague shared stations.
The timing is telling. With unsupervised Full Self-Driving hardware already rolling out across the lineup and Cybercab production targets looming, Tesla is shifting from vehicle development to ecosystem readiness.
Charging infrastructure has historically been the gating factor for ride-hailing scale; building it ahead of the vehicles signals confidence that regulatory and technical hurdles are nearing resolution.
Tesla has been spotted testing Cybercab units in Arizona over the past few months, as well.
Interestingly, the permits show V4 Superchargers in the plans, although Cybercab will likely utilize wireless charging:
Tesla Cybercab spotted with interesting charging solution, stimulating discussion
For Tesla, these Robotaxi-only Superchargers represent more than convenient parking spots. They are the first bricks in a vertically integrated autonomy platform—vehicles, energy, and software working in seamless concert.
It appears Tesla is preparing to begin building out Robotaxi-only Superchargers to avoid the congestion and keep its autonomous fleet charged up to get ride-hailers to their destinations.