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Tesla Model 3’s body structure is a strategic blend of aluminum and ultra high-strength steel

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New photos from Tesla Model 3’s Body Repair Tech Note reveal a metal composition for the vehicle’s structure that strikes a perfect balance between world class safety and cost effectiveness.

One might recall Tesla CEO Elon Musk giving a tonque-in-cheek response about Model 3’s 5-star safety rating during a speech in Fremont, California. “The Volvo [S60] is arguably the second safest car in the world”, said Musk while alluding to the fact that Model 3 takes top honors for being the safest car in the world.

Photos posted to Twitter and shared on Reddit illustrate just how Tesla has been able to achieve a Model 3 body structure design that’s lightweight and has unparalleled strength at an entry level price point.

Looking at a front quarter exploded view of the Model 3 body, one can see the various compositions of steel the Tesla engineers used across the machine-stamped, multi-layer structure.

Tesla uses three different grades of steel, from mild steel used on the outer body structure where it’s designed to absorb initial impacts, and high-strength, to ultra high-strength used in the vehicle’s core. For instance, the A-pillar and B-pillar (noted in red on the graphic) is fabricated from ultra high-strength steel in order to provide maximum rollover protection. Model 3’s front frame rail is a composition between high-strength and ultra high-strength steel, and serves as the main support for the front “crumple zone”.

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Tesla Model 3’s body repair manual notes that “Structural Pulling” is not allowed, meaning that any structural component that’s welded, weld-bonded, riveted, or rivet-bonded to the vehicle can not undergo a process wherein the straightening of structural parts are facilitated through a hydraulic pulling machine. Doing so would compromise the yield strength of the metals being used.

 

Also noted in the Model 3 structural diagram is the “underbelly” that serves as the main support for Model 3’s skateboard style battery pack, similar to what’s used in its older Model S and Model X siblings. The entire underside of the vehicle is fabricated from high-strength steel.

Side impact safety on the Model 3 is bolstered by a fully fortified closed steel structure in ultra high-strength steel. Looking at the crash test video showing a side-pole impact test performed on Tesla’s Model 3 and Volvo’s S60, one can easily see the level of deformity the Volvo has over the Model 3.

Lastly, lightweight aluminum is introduced in areas of the body structure that are less susceptible to accidental impact such as the trunk floor and wheel wells. Using aluminum helps Model 3 maintain a relatively light curb weight of 3,549 lbs. for the standard version and 3,814 lbs. for the Long Range Model 3 with larger (and heavier) battery pack.

All in all, Tesla’s use of various steels and aluminum in Model 3’s body structure can be seen as a learning experience and first iteration towards even more affordable and higher volume production down the road – Model Y.

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Tesla China delivery centers packed as Q4 2025 enters its final month

Fresh photos from delivery centers in the country show rows upon rows of Model Ys and Model 3s.

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Credit: Tesla China

Tesla’s delivery centers in China are filled with vehicles as the company ramps up for its final push in Q4 2025. Fresh photos from delivery centers in the country show rows upon rows of Model Ys and Model 3s, signaling strong end-of-quarter momentum.

A delivery push for Q4 2025

A recent aerial shot from a Tesla delivery center in China captures the company’s efforts to deliver as many vehicles as possible as the year comes to a close. As could be seen in the image, which was posted by on X by Tesla enthusiast Nic Cruz Patane, the facility was filled with numerous Model Y and Model 3 units, each vehicle seemingly ready to be handed over to customers.

Echoing the scene, another post, reportedly from two weeks prior, showed a similar scene in a Shanghai location, which was packed with Model Y units. X user Roberto Nores shared the photo, noting that the image also shows multiple Model Y Ls, a six-seat extended wheelbase version of the popular all-electric crossover. 

Towards a strong Q4 finish

China remains Tesla’s volume powerhouse, accounting for a good portion of the company’s global deliveries in recent quarters. That being said, reports did emerge in early November stating that the company only reached 26,006 retail sales during October, as noted in a CNEV Post report. The reasons for this remain to be seen, though a focus on exports could have been a contributing factor.

Tesla China does seem to be hinting at some momentum this November. Just recently, Tesla watchers observed that the order page for the Model Y in China shows a message informing customers that those who wish to guarantee delivery by the end of the year should purchase an inventory unit. This was despite the Model Y RWD and Model Y L showing an estimated delivery timeline of 4-8 weeks, and the Model Y Long Range RWD and Model Y Long Range AWD showing 4-13 weeks. 

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SpaceX’s Starship FL launch site will witness scenes once reserved for sci-fi films

A Starship that launches from the Florida site could touch down on the same site years later.

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Credit: SpaceX/X

The Department of the Air Force (DAF) has released its Final Environmental Impact Statement for SpaceX’s efforts to launch and land Starship and its Super Heavy booster at Cape Canaveral Space Force Station’s SLC-37.

According to the Impact Statement, Starship could launch up to 76 times per year on the site, with Super Heavy boosters returning within minutes of liftoff and Starship upper stages landing back on the same pad in a timeframe that was once only possible in sci-fi movies. 

Booster in Minutes, Ship in (possibly) years

The EIS explicitly referenced a never-before-seen operational concept: Super Heavy boosters will launch, reach orbit, and be caught by the tower chopsticks roughly seven minutes after liftoff. Meanwhile, the Starship upper stage will complete its mission, whether a short orbital test, lunar landing, or a multi-year Mars cargo run, and return to the exact same SLC-37 pad upon mission completion.

“The Super Heavy booster landings would occur within a few minutes of launch, while the Starship landings would occur upon completion of the Starship missions, which could last hours or years,” the EIS read.

This means a Starship that departs the Florida site in, say, 2027, could touch down on the same site in 2030 or later, right beside a brand-new stack preparing for its own journey, as noted in a Talk Of Titusville report. The 214-page document treats these multi-year round trips as standard procedure, effectively turning the location into one of the world’s first true interplanetary spaceports.

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Noise and emissions flagged but deemed manageable

While the project received a clean bill of health overall, the EIS identified two areas requiring ongoing mitigation. Sonic booms from Super Heavy booster and Starship returns will cause significant community annoyance” particularly during nighttime operations, though structural damage is not expected. Nitrogen oxide emissions during launches will also exceed federal de minimis thresholds, prompting an adaptive management plan with real-time monitoring.

Other impacts, such as traffic, wildlife (including southeastern beach mouse and Florida scrub-jay), wetlands, and historic sites, were deemed manageable under existing permits and mitigation strategies. The Air Force is expected to issue its Record of Decision within weeks, followed by FAA concurrence, setting the stage for rapid redevelopment of the former site into a dual-tower Starship complex.

SpaceX Starship Environmental Impact Statement by Simon Alvarez

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Tesla Full Self-Driving (FSD) testing gains major ground in Spain

Based on information posted by the Dirección General de Tráfico (DGT), it appears that Tesla is already busy testing FSD in the country.

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Credit: Grok Imagine

Tesla’s Full Self-Driving (Supervised) program is accelerating across Europe, with Spain emerging as a key testing hub under the country’s new ES-AV framework program.

Based on information posted by the Dirección General de Tráfico (DGT), it appears that Tesla is already busy testing FSD in the country.

Spain’s ES-AV framework

Spain’s DGT launched the ES-AV Program in July 2025 to standardize testing for automated vehicles from prototypes to pre-homologation stages. The DGT described the purpose of the program on its official website.

“The program is designed to complement and enhance oversight, regulation, research, and transparency efforts, as well as to support innovation and advancements in automotive technology and industry. This framework also aims to capitalize on the opportunity to position Spain as a pioneer and leader in automated vehicle technology, seeking to provide solutions that help overcome or alleviate certain shortcomings or negative externalities of the current transportation system,” the DGT wrote. 

The program identifies three testing phases based on technological maturity and the scope of a company’s operations. Each phase has a set of minimum eligibility requirements, and applicants must indicate which phase they wish to participate in, at least based on their specific technological development.

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Credit: DGT

Tesla FSD tests

As noted by Tesla watcher Kees Roelandschap on X, the DGT’s new framework effectively gives the green flight for nationwide FSD testing. So far, Tesla Spain has a total of 19 vehicles authorized to test FSD on the country’s roads, though it would not be surprising if this fleet grows in the coming months.

The start date for the program is listed at November 27, 2025 to November 26, 2027. The DGT also noted that unlimited FSD tests could be done across Spain on any national route. And since Tesla is already in Phase 3 of the ES-AV Program, onboard safety operators are optional. Remote monitoring would also be allowed. 

Tesla’s FSD tests in Spain could help the company gain a lot of real-world data on the country’s roads. Considering the scope of tests that are allowed for the electric vehicle maker, it seems like Spain would be one of the European countries that would be friendly to FSD’s operations. So far, Tesla’s FSD push in Europe is notable, with the company holding FSD demonstrations in Germany, France, and Italy. Tesla is also pushing for national approval in the Netherlands in early 2026.

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