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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 just tipped its hand on a major Cybercab feature as production hits Plaid Mode
Tesla has delivered a clear signal that its Robotaxi ambitions are shifting into high gear. On April 17, longtime factory observer and drone pilot Joe Tegtmeyer captured drone footage and still images showing approximately 14 freshly built Cybercabs parked in the outbound lot—each one conspicuously lacking a steering wheel.
Tesla just tipped its hand on a major Cybercab feature as it is putting production into Plaid Mode, but a clear indication of what the company plans to do with the vehicle is now apparent.
Tesla has delivered a clear signal that its Robotaxi ambitions are shifting into high gear, and it’s doing it with full autonomy in mind.
On April 17, longtime factory observer and drone pilot Joe Tegtmeyer captured drone footage and still images showing approximately 14 newly built Cybercabs parked in the outbound lot, each conspicuously lacking a steering wheel, and potentially pedals.
Tegtmeyer’s post highlighted the significance of this development: The images and video reveal sleek, two-seat Cybercabs in their final production form: no driver controls, no side mirrors, and the minimalist interior first unveiled at Tesla’s “We Robot” event in October 2024.
Something big has changed at Giga Texas with Cybercab production … ~ 14 in the outbound lot WITHOUT STEERING WHEELS!
Earlier this week, the production line has begun what we are all waiting for and I would expect to see many more starting on Monday, 4/20 🤠
A big step… pic.twitter.com/K17ZzBlQ8k
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) April 17, 2026
These units contrast with earlier test vehicles spotted at the factory’s crash-test area, which carried temporary steering wheels and pedals to meet current federal regulations during data-collection phases.
The outbound-lot vehicles appear complete, with production wheels, tire stickers, and the signature Cybercab styling ready for deployment.
This sighting represents a pivotal transition. Tesla designed the Cybercab from the ground up as a purpose-built robotaxi, engineered for unsupervised Full Self-Driving (FSD) operation. Removing manual controls eliminates cost, complexity, and weight while maximizing interior space and range.
The move also signals that Tesla has cleared initial validation hurdles and is now building vehicles to the exact specification intended for commercial robotaxi service.
Industry watchers note the timing aligns with Tesla’s broader rollout plans. Production of early Cybercabs began in late 2025 and early 2026, primarily for internal testing and regulatory compliance.
Federal Motor Vehicle Safety Standards currently limit vehicles without steering wheels to 2,500 units per year without exemption, a cap that Tesla is navigating through ongoing filings.
Tesla Cybercab spotted next to Model Y shows size comparison
The appearance of steering-wheel-free units in the outbound lot suggests the company is preparing a small initial fleet—likely for Austin pilot operations or further validation—while pushing for regulatory relief to scale output.
The development comes as Tesla ramps its dedicated Cybercab line at Gigafactory Texas. If the Monday surge materializes as predicted, observers expect dozens more units to accumulate rapidly.
With unsupervised FSD advancing and regulatory conversations ongoing, these wheel-less Cybercabs parked under the Texas sun represent more than hardware—they embody Tesla’s bet that autonomous mobility is no longer a prototype dream but an imminent reality.
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Tesla preps new Model Y trim for India, a once-elusive market
Tesla’s journey into India began with significant hurdles. For years, the electric vehicle giant faced steep import tariffs ranging from 70 percent to 110 percent on fully built vehicles, which dramatically inflated prices and stalled entry plans.
Tesla is preparing to bring its newest Model Y trim to India, a once-elusive market that was hesitant to allow any vehicles built outside the market into its automotive sector.
Now, it is preparing to allow China-built Model Y vehicles to come into the country, in an effort to expand sales and offer what is a widely-requested variant to Indian customers.
Tesla’s journey into India began with significant hurdles. For years, the electric vehicle giant faced steep import tariffs ranging from 70 percent to 110 percent on fully built vehicles, which dramatically inflated prices and stalled entry plans.
Elon Musk repeatedly criticized these duties as among the world’s highest, making premium EVs like the Model Y prohibitively expensive for most buyers in the price-sensitive market.
After prolonged negotiations and multiple delays, Tesla finally debuted in July 2025 with a quiet rollout focused on luxury segments. It opened showrooms in Mumbai and New Delhi, importing standard Model Y SUVs from its Shanghai Gigafactory.
Tesla China posts strong February wholesale growth at Gigafactory Shanghai
Yet the launch proved challenging: vehicles carried sticker prices near $70,000, leading to tepid demand. Bloomberg reported only about 600 orders in the first two months, while official data showed just 227 registrations for all of 2025—far below internal targets. By early 2026, the company offered discounts of up to ₹200,000 ($2,200) to clear unsold inventory.
Now, less than a year later, Tesla is demonstrating resilience and adaptability. According to a Bloomberg report on April 17, the company is preparing to launch the Model Y L—a six-seat, long-wheelbase variant with three-row seating—as early as next week.
This marks Tesla’s first new product introduction in India since its initial entry. Notably, the newest Model Y configuration, which debuted in China in 2025 and features extended space tailored for families, will once again be exported directly from Tesla’s Shanghai Gigafactory.
The move highlights a shift from early struggles to a more targeted approach, leveraging an existing platform to better suit Indian preferences for multi-generational, spacious SUVs without committing to immediate local production.
Tesla launches in India with Model Y, showing pricing will be biggest challenge
The Model Y L’s arrival underscores Tesla’s incremental strategy amid global EV headwinds and India’s unique challenges, including limited charging infrastructure and competition from local manufacturers.
While tariffs continue to keep pricing in the premium segment, the six-seater variant aims to broaden appeal beyond early luxury adopters by addressing practical family needs.
This evolution, from battling high barriers and disappointing initial sales to exporting its latest derivative model, signals cautious optimism.
Success with the Model Y L could strengthen Tesla’s foothold in one of the world’s most populous markets and potentially pave the way for deeper investments, such as localized manufacturing, should tariff relief or policy shifts materialize.
For now, the China-to-India supply chain represents a pragmatic bridge over the very obstacles that once made entry so difficult.
Elon Musk
Tesla’s golden era is no longer a tagline
Tesla “golden era” teaser video highlights the future of transportation and why car ownership itself may be the next thing to change.
The golden age of autonomous ridesharing is arriving, and Tesla is making sure we can all picture a future that looks like the future. A recent teaser posted to X shows a Cybercab parked outside a home, and with a clear message that your everyday life may soon look like this when the driverless vehicles shows up at your door.
Tesla has begun the rollout of its Robotaxi service across US cities, and the production of its dedicated, fully-autonomous Cybercab vehicle. The first Cybercab rolled off the Giga Texas assembly line on February 17, 2026, with volume production now targeted for this month. Additionally, the Robotaxi service built around it is already running, without human drivers, in US cities.
Tesla Cybercab production ignites with 60 units spotted at Giga Texas
The Cybercab is built without a steering wheel, pedals, or side mirrors, designed from the ground up for unsupervised autonomous operation. Musk described the manufacturing approach as closer to consumer electronics than traditional car production, targeting a cycle time of one unit every ten seconds at full scale.
Drone footage from April 13, 2026 captured over 50 Cybercab units on the Giga Texas campus, with several clustered near the crash testing facility. Musk has noted that Tesla plans to sell the Cybercab to consumers for under $30,000, and owners will be able to add their vehicles to the Tesla robotaxi network when not in personal use, potentially generating income to offset the vehicle’s purchase cost. That model changes the math on vehicle ownership in a meaningful way, making a car something closer to a depreciating asset that can also earn by paying itself off and generate a profit.
During Tesla’s Q4 earnings call, the company confirmed plans to expand the Robotaxi program to seven new cities in the first half of 2026, including Dallas, Houston, Phoenix, Miami, Orlando, Tampa, and Las Vegas. The service already runs without safety drivers in Austin, and public road testing of the Cybercab has expanded to five states, including California, Texas, New York, Illinois, and Massachusetts.
Golden era pic.twitter.com/AS6pX2dK8N
— Tesla Robotaxi (@robotaxi) April 16, 2026
Tesla just tipped its hand on a major Cybercab feature as production hits Plaid Mode
Tesla preps new Model Y trim for India, a once-elusive market
