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Tesla turns up vehicle safety with clever ‘crash can’ patent
Tesla’s electric cars are already among the safest vehicles on the road today with their impressive safety ratings. But even the best cars still have room for improvement, and one can count on Tesla to be the manufacturer that will do what it can to make its already-safe vehicles even safer. An example of this could be found in a recently published patent that describes a “crash can” that can help protect occupants better in the event of a collision.
The patent, titled “ADVANCED THIN-WALLED STRUCTURE FOR ENHANCED CRASH PERFORMANCE” describes a specific design for a “crash can,” a thin-walled metal structure that is built into the crash zones of a vehicle. These metal structures are built to absorb the energy of an impact, and are designed to deform in a stable manner during events such as a crash. Crash cans are typically a square, single-cell tube directly mounted to the front of the frame of the vehicle.
Tesla’s crash can patent takes the same concept but raises it up a couple of notches higher. Instead of using a simple square, single-cell tube, Tesla’s patent describes a “multi-cell structure that includes at least four hollow cuboids.” The four walls of the hollow cuboids meet at 90-degree angles and at least two of the cuboids share a wall. Tesla describes its design in the section below.
“In some embodiments a crash can for a vehicle includes a multi-cell structure that includes a hollow cuboid and four hollow isosceles trapezoidal prisms. The hollow cuboid has four walls and the four hollow isosceles trapezoidal prisms each have a long base, a short base, and two legs. The four hollow isosceles trapezoidal prisms are arranged around the hollow cuboid such that the long base of each hollow isosceles trapezoidal prism shares one of the walls of the hollow cuboid.”
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- (Credit: US Patent Office)
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- (Credit: US Patent Office)
Illustrations of Tesla’s “crash can” patent. (Credit: US Patent Office)
This updated design, while seemingly a minor change, actually improves the safety of a vehicle during a crash. According to Tesla, the crash can design in its recently-published patent provides a more stable deformation process. This increases the amount of energy that can be absorbed in a collision.
“One advantage of the various embodiments of the crash cans disclosed herein is that the multi-cell structure of the crash cans provides a more stable form of plastic deformation when the crash can is subject to the force of a collision relative to a single cell (tube) structure. Further, the various geometries described herein may further provide more stable plastic deformation relative to conventional geometries. As described herein, plastic deformation is the process of absorbing energy when the crash can is subject to a collision. Various exemplary crash cans provided herein increases plastic deformation, and thus the amount of energy absorbed, by increasing the probability that the crash cans buckle in a progressive manner. Thus, the multi-cell structure of the exemplary crash cans increases the probability that when subjected to axial force the crash cans will buckle in a stable top-down, progressive folding of the structure.
“Increasing plastic deformation in this manner grants the multi-cell crash can several advantages. For example, increasing plastic deformation in turn increases the amount of energy that will be absorbed during a collision, resulting in lower deceleration for the occupant(s) and critical components of a vehicle involved in a collision. This, in turn, results in an overall safer experience for the occupant(s) and critical components, providing for a lower chance of injury or damage. Additionally, increasing the probability that the multi-cell crash can buckles in a stable manner increases the predictability of how the crash can will react when subject to a collision, which in turn increases the predictability of how the rest of the vehicle will react. This allows for greater predictability of what an occupant will experience and allows for more precise planning on how to keep the occupant safe.”
The full text of Tesla’s novel “crash can” patent could be accessed here.
Among the carmakers in the auto segment today, Tesla is arguably the most obsessive when it comes to its vehicles’ safety. Each one of Tesla’s electric cars has performed well in crash tests, with the Model X SUV proving to be near-impossible to topple, and the Model 3 acing the safety tests of the NHTSA, Euro NCAP, ANCAP, and even the IIHS. With improvements such as those described in its recently-published “crash can” patent, Tesla’s electric cars today, as well as its upcoming vehicles, could prove even safer.
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Tesla Cybercab spotted next to Model Y shows size comparison
The Model Y is Tesla’s most-popular vehicle and has been atop the world’s best-selling rankings for the last three years. The Cybercab, while yet to be released, could potentially surpass the Model Y due to its planned accessible price, potential for passive income for owners, and focus on autonomy.
The Tesla Cybercab and Tesla Model Y are perhaps two of the company’s most-discussed vehicles, and although they are geared toward different things, a recent image of the two shows a side-by-side size comparison and how they stack up dimensionally.
The Model Y is Tesla’s most-popular vehicle and has been atop the world’s best-selling rankings for the last three years. The Cybercab, while yet to be released, could potentially surpass the Model Y due to its planned accessible price, potential for passive income for owners, and focus on autonomy.
Geared as a ride-sharing vehicle, it only has two seats. However, the car will be responsible for hauling two people around to various destinations completely autonomously. How they differ in terms of size is striking.
In a new aerial image shared by drone operator and Gigafactory Texas observer Joe Tegtmeyer, the two vehicles were seen side by side, offering perhaps the first clear look at how they differ in size.
Tesla Model Y vs. Tesla Cybercab:
✅ Overall Length:⁰Model Y: 188.7 inches (4,794 mm)⁰Cybercab: ~175 inches (≈4,445 mm)⁰→ Cybercab is about 13–14 inches shorter (roughly the length of a large suitcase).
✅ Overall Width (excluding mirrors):⁰Model Y: 75.6 inches (1,920 mm)… https://t.co/PsVwzhw1pe pic.twitter.com/58JQ5ssQIO
— TESLARATI (@Teslarati) March 25, 2026
Dimensionally, the differences are striking. The Model Y stretches roughly 188 inches long, 75.6 inches wide, excluding its mirrors, and stands 64 inches tall on a 113.8-inch wheelbase. The Cybercab measures approximately 175 inches in length, about a foot shorter, and just 63 inches wide.
That narrower stance gives the Cybercab a dramatically more compact silhouette, making it easier to maneuver in tight urban environments and park in standard spaces that would feel cramped for the Model Y. Height is also lower on the Cybercab, contributing to its sleek, coupe-like profile versus the Model Y’s taller crossover shape.
Visually, the contrast is unmistakable. The Model Y presents as a family-friendly SUV with conventional doors, a prominent hood, and a spacious glass roof.
The Cybercab eliminates the steering wheel and pedals entirely, creating a clean, futuristic cabin that feels more lounge than cockpit.
Its doors open in a distinctive, wide-swinging motion, and the body features smoother, more aerodynamic lines optimized for autonomy. Parked beside a Model Y, the Cybercab appears almost toy-like in width and length, yet its low-slung stance and minimalist design emphasize agility over bulk.
🚨 We caught up with the Tesla Cybercab today in The Bay Area: pic.twitter.com/9awXiK26ue
— TESLARATI (@Teslarati) March 24, 2026
Cargo capacity tells another part of the story. The Model Y offers generous real-world utility: 4.1 cubic feet in the front trunk and 30.2 cubic feet behind the rear seats, expanding to 72 cubic feet with the second row folded flat.
It comfortably swallows groceries, luggage, or sports equipment for five passengers. The Cybercab, designed for two riders, trades that volume for targeted efficiency.
It features a rear hatch with enough space for two carry-on suitcases and personal items, plenty for the typical robotaxi trip, while maintaining impressive legroom and headroom for its occupants.
In short, the Model Y prioritizes versatility and family hauling with its larger footprint and abundant storage. The Cybercab sacrifices size for simplicity, cost, and urban nimbleness.
At roughly 12 inches shorter and 12 inches narrower, it embodies Tesla’s vision for scalable, affordable autonomy: smaller on the outside, smarter inside, and ready to redefine how we move through cities.
The Cybercab and Model Y both will contribute to Tesla’s fully autonomous future. However, the size comparison gives a good look into how the vehicles are the same, and how they differ, and what riders should anticipate as the Cybercab enters production in the coming weeks.
Elon Musk
Elon Musk says Tesla is developing a new vehicle: ‘Way cooler than a minivan’
It sounds as if Tesla could be considering a new vehicle to fit the mold of what a larger family would need, and as fans have been demanding it for several years and the company is phasing out the Model X, its only family-geared vehicle, it sounds as if it could be the perfect time.
Tesla CEO Elon Musk said the company is developing a new vehicle, and it will be “way cooler than a minivan.”
It sounds as if Tesla could be considering a new vehicle to fit the mold of what a larger family would need, and as fans have been demanding it for several years and the company is phasing out the Model X, its only family-geared vehicle, it sounds as if it could be the perfect time.
There are a handful of things Musk could be talking about, and as many Tesla owners have wanted a vehicle along the lines of a minivan for hauling around their family, speculation has persisted about what the company would do in terms of developing something for that exact use case.
There were several options, and some of them seemed to be already available. Musk posted on X yesterday that the Cybertruck has three sets of isofix attachments and could fit three child seats or three adults, and it seemed to be a way to deflect plans for a new, larger vehicle as a Model Y L appeared to be present at Giga Texas.
There is also the Robovan, the large people mover that Tesla unveiled at the “We, Robot” back in 2024.
Something way cooler than a minivan is coming
— Elon Musk (@elonmusk) March 25, 2026
However, it seems Tesla could be developing something like a CyberSUV, something that is going to be large enough to haul around a car full of kids, but could be developed with the company’s aesthetic of the company’s most recent releases: this would likely include a light bar and a more sleek, futuristic look.
We’ve mocked up some potential looks for Tesla’s speculative vehicle in the past:
Tesla has teased the potential of a CyberSUV in the past, showing off clay models that it developed back in September in a teaser video called “Sustainable Abundance.”
Fans and owners have been calling for this development for a very long time, and it seems like Tesla might be ready to finally answer the call on a large SUV. With the segment being dominated by combustion engine vehicles, Tesla could truly disrupt the large SUVs that have been mainstays.
The Chevrolet Tahoe and GMC Yukon would feel some additional pressure, and it would be possible for Tesla to infiltrate some of those sales and pull consumers to electric powertrains.
As the Model S and Model X sunset process is truly hitting full swing, it might be time to consider Tesla’s next option in terms of vehicle development.
Elon Musk
Elon Musk’s $10 Trillion robot: Inside Tesla’s push to mass produce Optimus
Tesla’s surging Optimus job listings reveal a company sprinting from prototype to one million robot production.
Tesla is accelerating its push to bring the Optimus humanoid robot to high volume production, and its recent job listings tells the story as clearly as any earnings call.
With well over 100 Optimus related job openings now posted across its U.S. facilities, Tesla is signaling a critical pivot for the program, moving it from a captivating tech demo to a serious manufacturing endeavor. Roles span the full spectrum of the product lifecycle, from Robotics Software Engineers and Manufacturing Engineers to Mechanical Integration Engineers and AI Engineers focused on world modeling and video generation. One active listing for a Software Engineer on the Optimus team asks candidates to build scalable and reliable data pipelines for Optimus manufacturing lines and develop automation tools that accelerate analysis and visualization for mass manufacturing.
Tesla is racing toward a one million unit annual production target. The clearest signal yet that Tesla is treating Optimus as its primary business came on January 28, 2026, during the company’s Q4 2025 earnings call. Musk announced that Tesla is ending production of the Model S and Model X, and will repurpose those lines at its Fremont, California factory to build Optimus humanoid robots.
A production intent prototype of Optimus Version 3 is planned to be ready in early 2026, after which Tesla intends to build a one million unit production line with a targeted production start by the end of 2026. To support that ramp, Tesla broke ground on a massive new Optimus manufacturing facility at Gigafactory Texas in late 2025, with ambitions to eventually reach 10 million units per year.
Tesla Giga Texas to feature massive Optimus V4 production line
The business case for scaling this aggressively is rooted in labor economics. Musk has stated that “Optimus has the potential to be the biggest product of all time,” reasoning that if Tesla can produce capable humanoid robots at scale and reasonable cost, every task currently performed by human labor becomes a potential application. In a separate statement, Musk framed Optimus’s long term importance even more bluntly, saying it could surpass Tesla’s vehicle business in scale with the potential to generate $10 trillion in revenue.
The industries Tesla is targeting first are those most burdened by repetitive physical labor. Early applications include manufacturing assembly, material handling and quality inspection, as well as logistics tasks like loading, unloading, sorting, and transporting goods in warehouses and distribution centers. Longer term, Tesla’s vision is for Optimus to penetrate household, medical, and logistics scenarios at the scale of a smartphone rollout.
Tesla Cybercab spotted next to Model Y shows size comparison
Elon Musk says Tesla is developing a new vehicle: ‘Way cooler than a minivan’
Elon Musk’s $10 Trillion robot: Inside Tesla’s push to mass produce Optimus
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