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Tesla Model 3’s body structure is a strategic blend of aluminum and ultra high-strength steel
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”.
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.
Watch a Tesla Model 3 vs. Volvo S60 side-pole impact test pic.twitter.com/dXBQkstrdo
— Tesla (@Tesla) July 29, 2017
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.
Tesla has added the 15th automaker to the growing list of companies whose EVs can utilize the Supercharger Network this year, as BMW is the latest company to gain access to the largest charging infrastructure in the world.
BMW became the 15th company in 2025 to gain Tesla Supercharger access, after the company confirmed to its EV owners that they could use any of the more than 25,000 Supercharging stalls in North America.
Welcome @BMW owners.
Download the Tesla app to charge → https://t.co/vnu0NHA7Ab
— Tesla Charging (@TeslaCharging) December 10, 2025
Newer BMW all-electric cars, like the i4, i5, i7, and iX, are able to utilize Tesla’s V3 and V4 Superchargers. These are the exact model years, via the BMW Blog:
- i4: 2022-2026 model years
- i5: 2024-2025 model years
- 2026 i5 (eDrive40 and xDrive40) after software update in Spring 2026
- i7: 2023-2026 model years
- iX: 2022-2025 model years
- 2026 iX (all versions) after software update in Spring 2026
With the expansion of the companies that gained access in 2025 to the Tesla Supercharger Network, a vast majority of non-Tesla EVs are able to use the charging stalls to gain range in their cars.
So far in 2025, Tesla has enabled Supercharger access to:
- Audi
- BMW
- Genesis
- Honda
- Hyundai
- Jaguar Land Rover
- Kia
- Lucid
- Mercedes-Benz
- Nissan
- Polestar
- Subaru
- Toyota
- Volkswagen
- Volvo
Drivers with BMW EVs who wish to charge at Tesla Superchargers must use an NACS-to-CCS1 adapter. In Q2 2026, BMW plans to release its official adapter, but there are third-party options available in the meantime.
They will also have to use the Tesla App to enable Supercharging access to determine rates and availability. It is a relatively seamless process.
News
Tesla adds new feature that will be great for crowded parking situations
This is the most recent iteration of the app and was priming owners for the slowly-released Holiday Update.
Tesla has added a new feature that will be great for crowded parking lots, congested parking garages, or other confusing times when you cannot seem to pinpoint where your car went.
Tesla has added a new Vehicle Locator feature to the Tesla App with App Update v4.51.5.
This is the most recent iteration of the app and was priming owners for the slowly-released Holiday Update.
While there are several new features, which we will reveal later in this article, perhaps one of the coolest is that of the Vehicle Locator, which will now point you in the direction of your car using a directional arrow on the home screen. This is similar to what Apple uses to find devices:
Interesting. The location arrow in the Tesla app now points to your car when you’re nearby. pic.twitter.com/b0yjmwwzxN
— Whole Mars Catalog (@wholemars) December 7, 2025
In real time, the arrow gives an accurate depiction of which direction you should walk in to find your car. This seems extremely helpful in large parking lots or unfamiliar shopping centers.
Getting to your car after a sporting event is an event all in itself; this feature will undoubtedly help with it:
The nice little touch that Tesla have put in the app – continuous tracking of your vehicle location relative to you.
There’s people reporting dizziness testing this.
To those I say… try spinning your phone instead. 😉 pic.twitter.com/BAYmJ3mzzD
— Some UK Tesla Guy (UnSupervised…) (@SomeUKTeslaGuy) December 8, 2025
Tesla’s previous app versions revealed the address at which you could locate your car, which was great if you parked on the street in a city setting. It was also possible to use the map within the app to locate your car.
However, this new feature gives a more definitive location for your car and helps with the navigation to it, instead of potentially walking randomly.
It also reveals the distance you are from your car, which is a big plus.
Along with this new addition, Tesla added Photobooth features, Dog Mode Live Activity, Custom Wraps and Tints for Colorizer, and Dashcam Clip details.
🚨 Tesla App v4.51.5 looks to be preparing for the Holiday Update pic.twitter.com/ztts8poV82
— TESLARATI (@Teslarati) December 8, 2025
All in all, this App update was pretty robust.
Tesla CEO Elon Musk shaded Waymo in a post on X on Wednesday, stating the company “never really had a chance” and that it “will be obvious in hindsight.”
Tesla and Waymo are the two primary contributors to the self-driving efforts in the United States, with both operating driverless ride-hailing services in the country. Tesla does have a Safety Monitor present in its vehicles in Austin, Texas, and someone in the driver’s seat in its Bay Area operation.
Musk says the Austin operation will be completely void of any Safety Monitors by the end of the year.
🚨 Tesla vs. Waymo Geofence in Austin https://t.co/A6ffPtp5xv pic.twitter.com/mrnL0YNSn4
— TESLARATI (@Teslarati) December 10, 2025
With the two companies being the main members of the driverless movement in the U.S., there is certainly a rivalry. The two have sparred back and forth with their geofences, or service areas, in both Austin and the Bay Area.
While that is a metric for comparison now, ultimately, it will not matter in the coming years, as the two companies will likely operate in a similar fashion.
Waymo has geared its business toward larger cities, and Tesla has said that its self-driving efforts will expand to every single one of its vehicles in any location globally. This is where the true difference between the two lies, along with the fact that Tesla uses its own vehicles, while Waymo has several models in its lineup from different manufacturers.
The two also have different ideas on how to solve self-driving, as Tesla uses a vision-only approach. Waymo relies on several things, including LiDAR, which Musk once called “a fool’s errand.”
This is where Tesla sets itself apart from the competition, and Musk highlighted the company’s position against Waymo.
Jeff Dean, the Chief Scientist for Google DeepMind, said on X:
“I don’t think Tesla has anywhere near the volume of rider-only autonomous miles that Waymo has (96M for Waymo, as of today). The safety data is quite compelling for Waymo, as well.”
Musk replied:
“Waymo never really had a chance against Tesla. This will be obvious in hindsight.”
Waymo never really had a chance against Tesla. This will be obvious in hindsight.
— Elon Musk (@elonmusk) December 10, 2025
Tesla stands to have a much larger fleet of vehicles in the coming years if it chooses to activate Robotaxi services with all passenger vehicles. A simple Over-the-Air update will activate this capability, while Waymo would likely be confined to the vehicles it commissions as Robotaxis.
Tesla adds 15th automaker to Supercharger access in 2025
Tesla adds new feature that will be great for crowded parking situations
