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 Semi expands pilot program to Texas logistics firm: here’s what they said
Mone said the Tesla Semi it put into its fleet for this test recorded 1.64 kWh per mile efficiency, beating Tesla’s official 1.7 kWh per mile target and delivering a massive leap over conventional diesel trucks.
Tesla has expanded its Semi pilot program to a new region, as it has made it to Texas to be tested by logistics from Mone Transport. With the Semi entering production this year, Tesla is getting even more valuable data regarding the vehicle and its efficiency, which will help companies cut expenditures.
Mone Transport operates in Texas and on the Southern border, and it specializes in cross-border U.S.-Mexico freight operations. After completing some rigorous testing, Mone shared public results, which stand out when compared to efficiency metrics offered by diesel vehicles.
“Mone Transport recently had the opportunity to put the Tesla Semi to the test, and we’re thrilled with the results! Over 4,700 miles of operations at 1.64 kWh/mile in our Texas operation. We’re committed to providing zero-emission transportation to our customers!” the company said in a post on X.
🚨 Mone Transport just recorded an extremely impressive Tesla Semi test:
1.64 kWh per mile over 4,700 miles! https://t.co/xwS2dDeomP pic.twitter.com/oLZHoQgXsu
— TESLARATI (@Teslarati) March 10, 2026
Mone said the Tesla Semi it put into its fleet for this test recorded 1.64 kWh per mile efficiency, beating Tesla’s official 1.7 kWh per mile target and delivering a massive leap over conventional diesel trucks.
Comparable Class 8 diesel semis, typically achieving 6-7 miles per gallon, consume roughly 5.5 kWh per mile in energy-equivalent terms, meaning the Semi uses three to four times less energy while also producing zero tailpipe emissions.
Tesla Semi undergoes major redesign as dedicated factory preps for deliveries
The performance of the Tesla Semi in Mone Transport’s testing aligns with data from other participants in the pilot program. ArcBest’s ABF Freight Division logged 4,494 miles over three weeks in 2025, averaging 1.55 kWh per mile across varied routes, including a grueling 7,200-foot Donner Pass climb. The truck “generally matched the performance of its diesel counterparts,” the carrier said.
PepsiCo, which operates the largest known Semi fleet, recorded 1.7 kWh per mile in North American Council for Freight Efficiency testing. Additional pilots showed similar gains: DHL hit 1.72 kWh per mile, and Saia achieved 1.73 kWh per mile.
These metrics underscore the Semi’s ability to slash operating costs through superior efficiency, lower maintenance, and zero-emission operation. As charging infrastructure scales and production ramps toward 2026 targets, participants like Mone Transport are proving electric semis can seamlessly integrate into freight networks, accelerating the industry’s shift to sustainable, high-performance trucking.
Tesla continues to prep for a more widespread presence of the Semi in the coming months as it recently launched the first public Semi Megacharger site in Los Angeles. It is working on building out infrastructure for regional runs on the West Coast initially, with plans to expand this to the other end of the country in the coming years.
Elon Musk
SpaceX weighs Nasdaq listing as company explores early index entry: report
The company is reportedly seeking early inclusion in the Nasdaq-100 index.
Elon Musk’s SpaceX is reportedly leaning toward listing its shares on the Nasdaq for a potential initial public offering (IPO) that could become the largest in history.
As per a recent report, the company is reportedly seeking early inclusion in the Nasdaq-100 index. The update was reported by Reuters, citing people familiar with the matter.
According to the publication, SpaceX is considering Nasdaq as the venue for its eventual IPO, though the New York Stock Exchange is also competing for the listing. Neither exchange has reportedly been informed of a final decision.
Reuters has previously reported that SpaceX could pursue an IPO as early as June, though the company’s plans could still change.
One of the publication’s sources also suggested that SpaceX is targeting a valuation of about $1.75 trillion for its IPO. At that level, the company would rank among the largest publicly traded firms in the United States by market capitalization.
Nasdaq has proposed a rule change that could accelerate the inclusion of newly listed megacap companies into the Nasdaq-100 index.
Under the proposed “Fast Entry” rule, a newly listed company could qualify for the index in less than a month if its market capitalization ranks among the top 40 companies already included in the Nasdaq-100.
If SpaceX is successful in achieving its target valuation of $1.75 trillion, it would become the sixth-largest company by market value in the United States, at least based on recent share prices.
Newly listed companies typically have to wait up to a year before becoming eligible for major indexes such as the Nasdaq-100 or S&P 500.
Inclusion in a major index can significantly broaden a company’s shareholder base because many institutional investors purchase shares through index-tracking funds.
According to Reuters, Nasdaq’s proposed fast-track rule is partly intended to attract highly valued private companies such as SpaceX, OpenAI, and Anthropic to list on the exchange.
Elon Musk
The Boring Company’s Prufrock-2 emerges after completing new Vegas Loop tunnel
The new tunnel measures 2.28 miles, making it the company’s longest single Vegas Loop tunnel to date.
The Boring Company announced that its Prufrock-2 tunnel boring machine (TBM) has completed another Vegas Loop tunnel in Las Vegas. The company shared the update in a post on social media platform X.
According to The Boring Company’s post, the new tunnel measures 2.28 miles, making it the company’s longest single Vegas Loop tunnel to date.
The new tunnel marks the fourth tunnel constructed near Westgate Las Vegas as the Vegas Loop network continues expanding across the city.
The Boring Company also noted that the new tunnel surpassed its previous internal record of 2.26 miles for a single Vegas Loop segment.
Construction of the tunnel involved moving roughly 68,000 cubic yards of dirt. The excavation process also used about 4.8 miles of continuous conveyor belt, powered by six motors totaling 825 horsepower.
The Boring Company’s Prufrock-series all-electric tunnel boring machines are designed to support the rapid expansion of company’s underground transportation projects, including the growing Vegas Loop network. Prufrock machines are designed for reusability, thanks in no small part to their capability to be deployed and retrieved easily through their “porposing” feature.
The Vegas Loop, specifically the Las Vegas Convention Center (LVCC) Loop segment, has already been used during major events. Most recently, the LVCC Loop supported the 2026 CONEXPO-CON/AGG construction trade show, which was held from March 3-7, 2026.
As per The Boring Company, the LVCC Loop transported roughly 82,000 passengers across the convention center campus during the event’s duration.
CONEXPO-CON/AGG is one of the largest construction trade shows in North America, drawing more than 140,000 construction professionals from 128 countries this year.
The LVCC Loop forms the initial segment of the broader Vegas Loop network, which remains under active development as The Boring Company continues building new tunnels throughout the city.