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Tesla turns up vehicle safety with clever ‘crash can’ patent

Tesla Model 3 undergoes crash testing. (Credit: ANCAP Safety Ratings)

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6 years ago

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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.”

Illustrations of Tesla’s “crash can” patent. (Credit: US Patent Office)

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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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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 begins production of new Model Y trim at Giga Berlin

Tesla announced on Monday that its Model Y Standard configuration was officially being built at Giga Berlin, less than one month after the company officially announced the configuration early last month.

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1 hour ago

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November 4, 2025

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Credit: Tesla

Tesla has begun production of the new Model Y trim at Gigafactory Berlin, the company’s production plant in Germany.

Tesla announced on Monday that its Model Y Standard configuration was officially being built at Giga Berlin, less than one month after the company officially announced the configuration early last month.

On October 7, Tesla announced the launch of the Model 3 and Model Y Standard trim levels, its answer to the call for affordable EVs within its lineup and its response to the loss of the $7,500 electric vehicle tax credit.

On October 3, Tesla started production of the vehicles in Germany:

The Standard iteration of the Model Y is void of many of the more premium features that are available in the Rear-Wheel-Drive, All-Wheel-Drive, and Performance trims of the vehicle are equipped with.

A few of the features of the Model Y Standard are:

  • Single Motor configuration
  • No rear touchscreen
  • Textile seats with vegan leather, instead of all vegan leather
  • 320-mile range
  • No glass roof

The launch of the Model Y Standard was truly a move to help Tesla get vehicles into the sub-$40,000 price point, and although many consumers were hoping to see the company get closer to $30,000 with these cars, this is a great starting point.

Deliveries in the United States have already started, and it seems it will be a vehicle that will do one of two things: either push some consumers to finally make the jump to Tesla, or it will give car buyers another reason to buy the Premium trims, as they may feel the lack of features is not a good enough deal.

This is something we saw with the Cybertruck’s Rear-Wheel-Drive configuration, which launched last year and ended up being more of the latter option listed above.

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The Tesla Model Y Standard is actually a great deal in Europe

It was only a $10,000 discount from the All-Wheel-Drive Cybertruck, but it also did not have adaptive air suspension, premium interiors, or the powered tonneau cover, which many people felt was too much of a sacrifice.

The Rear-Wheel-Drive Cybertruck was discontinued only a few months later.

It does not seem as if this is the case with the Model Y Standard, which already seems to be an attractive option to some buyers.

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Tesla begins wide rollout of Full Self-Driving v14 to Cybertruck

Published

16 hours ago

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November 3, 2025

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Credit: Weibo (via YYDS on X)

Tesla has officially begun the wide rollout of Full Self-Driving (Supervised) v14 to the Cybertruck about a month after the company started rolling it out to other vehicles in the fleet.

On Monday, Tesla officially started rolling out v14.1.5 to Cybertruck owners, the first FSD v14 rollout for owners of the all-electric pickup.

Owners have been anxiously waiting for Tesla to begin the wide release of v14 to Cybertruck, as the company said it would refine the suite for the vehicle.

Tesla has finally started rolling out to many owners, who are reporting that their Cybertrucks are downloading Software Update 2025.38.8.5, which contains FSD v14.1.5:

Tesla has to be more cautious with rolling out FSD on the Cybertruck than on other vehicles for a few reasons. Initially, the Cybertruck utilizes an all-wheel steering system that turns differently than the S3XY lineup. This creates a challenge for the Tesla AI team as they have to cater to this specific maneuvering change.

Additionally, the Cybertruck is much larger, and the exterior cameras responsible for seeing the vehicle’s surroundings are placed differently than those of the other vehicles.

This requires additional calibration to ensure safety.

The full release notes for Full Self-Driving v14.1.5 are as follows:

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  • Added Arrival Options for you to select where FSD should park: in a Parking Lot, on the Street, in a Driveway, in a Parking Garage, or at the Curbside.
  • Added handling to pull over or yield for emergency vehicles (e.g. police cars, fire trucks, ambulances).
  • Added navigation and routing into the vision-based neural network for real-time handling of blocked roads and detours.
  • Added additional Speed Profile to further customize driving style preference.
  • Improved handling for static and dynamic gates.
  • Improved offsetting for road debris (e.g. tires, tree branches, boxes).
  • Improve handling of several scenarios including: unprotected turns, lane changes, vehicle cut-ins, and school buses.
  • Improved FSD’s ability to manage system faults and recover smoothly from degraded operation for enhanced reliability.
  • Added alerting for residue build-up on interior windshield that may impact front camera visibility. If affected, visit Service for cleaning!

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Elon Musk shuts down Tesla ‘AMG’ division speculation: ‘Focus is autonomy’

“I think it’s best to leave that to the custom shops. Tesla’s focus is autonomous cars, building futuristic autonomous cars. We want the future to look like the future.”

Published

18 hours ago

on

November 3, 2025

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Credit: Unplugged Performance

Tesla CEO Elon Musk was asked by Joe Rogan late last week whether the company would ever consider establishing an “AMG division” like Mercedes-Benz has established for powerful, race-inspired vehicles.

However, Musk turned down any talk of that, highlighting that the company is laser-focused on autonomous vehicles, seemingly hinting that any distraction from autonomy would be a detriment to the future.

Rogan drives a Tesla Model S himself, but it is not your run-of-the-mill all-electric sedan. Already outfitted with the Plaid powertrain that Tesla developed, Rogan took his vehicle to Unplugged Performance for a true performance outfitting.

The vehicle is completely overhauled with performance parts and seats. Known as the Model S-APEX, Rogan took delivery of it from Unplugged in January.

Rogan asked Musk on Friday during his most recent appearance on the Joe Rogan Experience podcast whether Tesla would ever establish an “AMG division” that would focus on catering Teslas to performance-based standards.

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Musk said:

“I think it’s best to leave that to the custom shops. Tesla’s focus is autonomous cars, building futuristic autonomous cars. We want the future to look like the future.”

Tesla fans have said for years that the company should consider acquiring Unplugged Performance and its Upfit Tesla division, which recently outfitted the Las Vegas Metropolitan Police Department’s fleet of Cybertruck cruisers.

However, it seems Tesla will keep things separate. Musk is primarily focused on autonomy, which will drive the technology forward and drive shareholder growth. Something like an outfitter for performance would be a cool thing for the owners who have the interest and the money.

It’s not a tremendous revenue driver or anything that would contribute to the financial state of the company. Mercedes-Benz, for example, is more accessible for consumers as it sold over 140,000 units from its AMG brand in 2024.

Tesla Model Y driver starts race in reverse, still wins against AMG SUV

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It helps with driving revenue higher by as much as 15 percent compared to similar models that are not AMGs. However, would Tesla see this much of a benefit? Likely not, because the Performance trim already caters to many owners.

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