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Tesla’s aluminum alloys patent hints at ultra-tough EVs that are cheaper to produce

Credit: Idea Group/YouTube

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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. 

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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

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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. 

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Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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Tesla FSD mocks BMW human driver: Saves pedestrian from near miss

Tesla FSD anticipated a BMW driver’s lane drift before the human behind the wheel could react.

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A video posted to r/TeslaFSD this week put a sharp spotlight on Tesla’s Full Self-Driving (FSD) software being able to react to pedestrian intent than an actual human driver behind the wheel. In the Reddit clip, a BMW driver can be seen rolling through a neighborhood street completely unaware of a pedestrian stepping in to cross. At the same time, a Tesla  driving on FSD had already begun slowing down before the pedestrian even began their attempt to cross the street The BMW kept moving, prompting the pedestrian to hop back, while the Tesla came to a stop and provide right-of-way for the human to safely cross.

That gap between what the BMW driver saw and what FSD had already processed is the story. Tesla FSD wasn’t reacting to a person in the street, rather it was reading the signals that a person was about to enter it based on the pedestrian’s movement, trajectory, and their trajectory to telegraph intent.

Tesla’s FSD is now built on an end-to-end neural network trained on billions of real-world miles, learning to interpret subtle human behavioral cues the same way an experienced human driver does instinctively. The difference is consistency. A human driver distracted for two seconds misses what FSD does not.

Tesla sues California DMV over Autopilot and FSD advertising ruling

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Reddit commenters in the thread were blunt about the BMW driver’s failure, with several pointing out that the pedestrian was visible well before the crossing. One response put it plainly that the car on FSD saw the situation developing before the human in the other car had registered there was a situation at all.

Tesla has published data showing FSD (Supervised) is 54% safer than a human driver, accumulated across billions of miles driven on the system. Elon Musk has said FSD v14 will outperform human drivers by a factor of two to three, and that v15 has “a shot” at a 10x improvement. Pedestrian safety is where the stakes are highest, and where intent prediction closes the gap fastest. At 30 mph, a car covers roughly 44 feet per second. An extra second of awareness from reading a person’s body language rather than waiting for them to step out is often the difference between a near miss and a fatality.

Video and community discussion: r/TeslaFSD on Reddit

FSD saves man from becoming a pancake. BMW driver nearly flattens him.
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Tesla Robotaxi gets a small but significant change

In the world of Tesla, where billion-dollar battery breakthroughs and autonomy milestones dominate headlines, a quiet design update can still pack a punch.

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Credit: David Moss | X

In the world of Tesla, where billion-dollar battery breakthroughs and autonomy milestones dominate headlines, a quiet design update can still pack a punch.

Last week in downtown Austin, sharp-eyed observers spotted a subtle but telling evolution on the Cybercab: a new “ROBOTAXI” logo graphic now graces the vehicle’s doors at Tesla’s Autonomy Popup.

What looks at first glance like a minor stylistic choice is, in fact, a deliberate rebranding move that hints at how the company envisions its robotaxi fleet fitting into everyday life.

The updated lettering is bold, graffiti-inspired, and unapologetically street-smart. Rendered in black with dripping white accents and a glowing yellow outline, the font evokes urban energy and playful irreverence.

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Gone is the sleek, minimalist typography that defined earlier Cybercab prototypes. In its place is something more human, almost rebellious.

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The new logo pops against the Cybercab’s smooth, metallic body, turning the autonomous pod into a rolling piece of public art rather than just another futuristic taxi.

Designers know that fonts are silent brand ambassadors. They shape perception before a single ride is taken. Tesla’s classic sans-serif aesthetic screams precision engineering and Silicon Valley cool.

The new Robotaxi script leans into accessibility and fun, suggesting the vehicle is approachable, not intimidating. For a product meant to ferry strangers through city streets 24/7, that matters. It signals that the robotaxi isn’t reserved for tech elites; it’s for everyone.

Tesla Cybercab spotted next to Model Y shows size comparison

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The timing is no accident. With regulatory approvals for unsupervised autonomy advancing and Tesla preparing to scale Cybercab production, the company is shifting from prototype showcase to fleet deployment.

A fresh logo helps differentiate the vehicles visually in dense urban environments—crucial for rider recognition and brand recall. It also aligns with Elon Musk’s long-standing ethos: make the future feel exciting, not sterile.

Small changes like this often foreshadow a larger strategy. Tesla has always obsessed over details—door handles, screen interfaces, even the curvature of a steering wheel.

Updating the Robotaxi font reflects the same meticulous care now applied to consumer-facing autonomy. It’s not just paint on metal; it’s a statement that the ride of the future should feel personal, memorable, and undeniably cool.

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In an industry racing toward self-driving fleets, Tesla’s willingness to evolve even the smallest visual cues shows confidence. A font won’t launch the robotaxi network, but it might just help millions climb aboard with a smile.

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Tesla makes latest announcement on Model S and Model X

The announcement follows Tesla CEO Elon Musk’s statement on the Q4 2025 earnings call in late January. Musk described the decision as an “honorable discharge” for the two vehicles, noting that production would wind down in Q2 2026.

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Credit: Tesla

Tesla has officially begun winding down production of its flagship Model S and Model X in the United States, notifying owners via email that the long-running models will soon reach the end of the line.

The email, sent to U.S. customers on March 27, opens with gratitude. “Model S and Model X marked the beginning of the world’s transition to electric transportation,” it reads. “These vehicles also made it possible for Tesla to develop the technology that would move our world toward autonomy.”

Tesla officially begins sunset of Model S and Model X

It then delivers the news directly: “As we make way for this autonomous future, Model S and Model X production will be ending. If you’d like to bring home a new Model S or Model X, order yours soon from our limited inventory.”

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The message closes with a simple thank-you: “Thank you for being part of our journey.”

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The announcement follows Tesla CEO Elon Musk’s statement on the Q4 2025 earnings call in late January. Musk described the decision as an “honorable discharge” for the two vehicles, noting that production would wind down in Q2 2026.

The move frees factory floor space at Fremont, California, for next-generation manufacturing, including Optimus humanoid robots and the upcoming Robotaxi platform.

Introduced in 2012 and 2015, respectively, the Model S and Model X were Tesla’s original halo cars. They proved EVs could outperform gasoline luxury vehicles in acceleration, range, and tech features while pioneering over-the-air updates and early autonomy hardware.

Although they never matched the volume of the Model 3 and Model Y, their engineering breakthroughs laid the foundation for the company’s current lineup and full self-driving development.

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Early adopters highlighted how the cars convinced them to invest in Tesla stock and the EV movement. Some U.S. owners who had not yet received the note voiced mild frustration, and international customers confirmed the outreach remains U.S.-only for now.

Tesla has not detailed an exact final production date beyond the Q2 2026 target or confirmed immediate replacements. Speculation continues about a possible Cybertruck-derived SUV, but the company’s public focus has shifted squarely to autonomy and robotics.

For buyers still interested in the S or X, the window is closing. Inventory is described as limited, and Tesla’s Korean division has already set a March 31 cutoff for new orders in that market. The email serves as both a farewell and final sales push, an elegant close to a chapter that helped define modern electric driving.

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