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Tesla patent points to battery cell improvements with clever deformation detection process
A recent patent published late August has revealed that Tesla is working on a monitoring system and apparatus that will allow the electric car maker to detect deformations in battery cells in a more effective manner.
Tesla’s patent application, titled “Apparatus and Method for Detection of Deformation in Battery Cells,” notes that battery cycle life is among the most crucial parameters to ensure optimal performance in machines such as electric vehicles and energy storage devices. Over the course of their lifetime, battery cells will be subjected to multiple charge and discharge cycles, at times in vastly varying conditions and environments.
As noted by the company in its patent application, there are instances when cells operate in an environment where the ambient temperature may intermittently surge to levels above the stable thermal temperature for normal operations. Cells could also be subjected to high charge and discharge rates and large periodic loads, which could result in significant heating, among other reactions.
Subjected to these factors, battery cells could experience several effects, such as the thickening of electrodes or the volume expansion of electrochemically active materials within the cell itself. These expansions could ultimately result in cells experiencing deformation, which could, in turn, result in both reversible and irreversible mechanical strain, as well as the potential degradation of the battery’s electrodes.
These battery cell deformations are traditionally monitored using strain gauges or optical gauges that exclusively detect and evaluate deformations at single points in a cell. Tesla noted that this system has space for improvements, since optical evaluations might not provide the correct status of deformation across the entire surface of a battery. This could result in strain and deformation measurements that are inaccurate.
With these factors in mind, Tesla has come up with a deformation detection apparatus that enables the contactless detection of deformations and/or swelling of the battery across the entire surface of the cell itself. Tesla describes the deformation detection apparatus as follows.
“A deformation detection apparatus includes a cell movement-control assembly to handle a linear motion and a rotational motion of a battery cell, a body that supports the cell movement-control assembly, a digital micrometer, and control circuitry. The control circuitry controls a displacement of the battery cell between a first position and a second position along a longitudinal axis through a scanning region of the digital micrometer and a plurality of rotational positions of the battery cell at a plurality of charge states and a plurality of discharge states. The control circuitry measures a plurality of outer diameter values of the battery cell for a plurality of linear positions and a plurality of rotational positions along the longitudinal axis of the battery cell and determines a change in a geometrical shape (deformation and/or strain) of the battery cell for the plurality of linear positions and the plurality of rotational positions.”
According to the electric car maker, the battery cell deformation monitoring process outlined in its patent will provide advantages over traditional monitoring methods.
“The disclosed apparatus, such as the apparatus 100 and method of determination of deformations in the battery cell 112 advantageously provides a contactless solution for deformation detection in the battery cells, as compared to conventional contact-based solutions. Further, instead of measuring the plurality of outer diameter values/strain values at a specific point in time, the disclosed apparatus 100 advantageously facilitates measurement of the plurality of outer diameter values/strain values at a plurality of points on the battery cell 112. The apparatus 100 enables detection of localized/non-localized deformation regions on the battery cell 112, which may exhibit signs of deformation at different charge/discharge states at different points in time.”
Tesla’s recently published patent application for its new battery cell deformation detection apparatus could be accessed in full here.
The implications of Tesla’s recent patent are notable. By adopting its deformation detection system, the company would be able to evaluate the quality of its cells and their operating limits more effectively. This could open the doors to improvements in the company’s batteries, which could, in turn, result in even more range and performance for Tesla’s electric vehicles.
Tesla holds a notable lead among automakers in terms of battery technology, as exhibited by the company’s electric vehicles’ vastly superior range compared to the competition. This is represented by Tesla’s recent “Raven” update to the 100 kWh Model X, which allowed the SUV to travel 325 miles in one charge. This is notably impressive, considering that the Audi e-tron, a smaller, lighter vehicle equipped with a 95 kWh battery pack (5% smaller than the Model X), is only EPA-rated for 204 miles per charge (38% less range than Tesla’s larger, heavier vehicle). A report from German business newspaper Wirtschaftswoche has also determined that Tesla’s batteries for the Model 3 have over four times less cobalt compared to the batteries utilized by Volkswagen today.
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Tesla Robotaxi appears to be heading to a new U.S. city
Things are expanding for Robotaxi, but the big sign that it is really moving along greatly will be with the expansion to a new city. Tesla has not gone outside of Austin or the Bay Area as of yet, and launching in a new city will be a great indicator of progress.
Tesla Robotaxi appears to be heading to a new U.S. city, and although the company has revealed plans to launch in six new metros this year, it has yet to establish a new location outside of Austin and the Bay Area of California, where it has operated since last Summer.
A lot full of Model Y vehicles was spotted in Henderson, a town just north of Las Vegas, but there seems to be more than just this hint indicating that the Sin City will be the next location to offer potentially driverless rides in a Tesla using its Full Self-Driving suite.
These Model Ys are not your typical vehicles, as they are fitted with hardware that is only on Robotaxis: a rear camera washer is the dead giveaway:
🚨 These rear camera washers are only present on Robotaxi vehicles
Maybe Las Vegas is the next city to get the Robotaxi suite 😀 https://t.co/my3da5L4zc pic.twitter.com/jYFQuX1j2E
— TESLARATI (@Teslarati) March 17, 2026
The photos and video of the lot were taken by TheZacher on X, who spotted the Model Y fleet in the Henderson parking lot.
The rear camera washer is the main piece of evidence here that indicates Tesla could be looking to expand Robotaxi to Las Vegas, a major ride-hailing hot spot, as it is one of the biggest tourist attractions in the United States. Ride-sharing is a major industry in Vegas, especially for those who are staying off the Strip.
Tesla has also been extremely transparent that Vegas is on its radar for the Robotaxi fleet, as it revealed last year that it was one of five new U.S. cities that it planned to launch the ride-hailing service in this year.
Tesla confirms Robotaxi is heading to five new cities in the U.S.
The others were Phoenix, Dallas, Houston, and Miami.
Things are expanding for Robotaxi, but the big sign that it is really moving along greatly will be with the expansion to a new city. Tesla has not gone outside of Austin or the Bay Area as of yet, and launching in a new city will be a great indicator of progress.
It will also give Tesla a new benchmark against rival company Waymo, which has operated in Las Vegas for some time.
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Tesla Roadster gets new unveiling date once again
Musk announced last year that the unveiling, which initially happened back in 2018, would take place on April Fool’s Day. Initial deliveries at the 2018 event were slotted for 2020, but delays in the project, as well as prioritization of other things, continued to push the Roadster back.
The Tesla Roadster is perhaps the most anticipated vehicle in the company’s history, but those who have been waiting anxiously for it will have to push their timelines back once again.
Tesla CEO Elon Musk has revealed that the company is once again pushing back the unveiling event that was originally planned for April 1. It will now take place “probably in late April.”
True.
New Roadster unveil probably in late April. https://t.co/NShZxpK5cI
— Elon Musk (@elonmusk) March 17, 2026
Musk announced last year that the unveiling, which initially happened back in 2018, would take place on April Fool’s Day. Initial deliveries at the 2018 event were slotted for 2020, but delays in the project, as well as prioritization of other things, continued to push the Roadster back.
There has been so much hype about the Roadster that people are right to be excited about the prospect of its existence.
Musk’s most recent rumblings about the vehicle came last Fall, when he appeared on the Joe Rogan Experience podcast, where he once again hinted the car would be able to hover for a short period.
He said:
“Whether it’s good or bad, it will be unforgettable. My friend Peter Thiel once reflected that the future was supposed to have flying cars, but we don’t have flying cars. I think if Peter wants a flying car, he should be able to buy one…I think it has a shot at being the most memorable product unveiling ever. [It will be unveiled] hopefully before the end of the year. You know, we need to make sure that it works. This is some crazy technology in this car. Let’s just put it this way: if you took all the James Bond cars and combined them, it’s crazier than that.”
Additionally, he said the vehicle would not be something that would prioritize safety. Musk said that “If safety is your number one goal, do not buy the Roadster.” It’s made for speed and excitement, not for grocery-getting.
Elon Musk just said some crazy stuff about the Tesla Roadster
As the April 1 unveiling event that was originally planned was nearing without any communication to fans, media, or anyone who would potentially be in attendance, it seemed to be pretty obvious that Tesla was not ready to pull the trigger on the event quite yet.
There could be some last-minute things to finalize, or it could be something else. One thing is for certain, though: we are not super surprised that things were moved back.
Tesla has definitely been putting some things in motion for the Roadster. A few months back, Tesla started to ramp up hiring for the Roadster, and earlier in March, it submitted a patent application for a new seat design.
Elon Musk
Tesla named by U.S. Gov. in $4.3B battery deal for American-made cells
What began as an open secret in the energy industry was confirmed by the U.S. Department of the Interior on Monday: Tesla is the buyer behind LG Energy Solution’s blockbuster $4.3 billion battery supply agreement.
What began as an open secret in the energy industry is becoming more real after the U.S. Department of the Interior named Tesla as the stakeholder in the LG Energy Solution’s blockbuster $4.3 billion battery supply agreement.
Tesla and LG Energy Solution are expanding their partnership to build a LFP prismatic battery cell manufacturing facility in Lansing, Michigan, launching production in 2027. The announcement, made as part of the Indo-Pacific Energy Security Summit results, ends months of speculation.
“American-made cells will power Tesla’s Megapack 3 energy storage systems produced in Houston, creating a robust domestic battery supply chain.”, notes a press release on the U.S. Department of the Interior website.
Tesla has long utilized China’s Contemporary Amperex Technology Co. (CATL), the world’s largest LFP battery maker, as one of its primary suppliers. That relationship made financial sense for years, considering that Chinese LFP cells were cheap, abundant, and reliable. But with escalated tariffs on Chinese imports and an increasingly growing Tesla Energy business that’s particularly reliant on LFP cells for products including its Megapack battery storage units designed for utilities and large-scale commercial projects.
The announcement of a deepened partnership between LG Energy Solution and Tesla has strategic logic for both parties. For Tesla, it secures a tariff-compliant, domestically produced battery supply for its fast-growing energy division. LGES, now producing LFP batteries in Michigan, becomes the only major supplier currently scaling U.S. production, outpacing rivals like Samsung SDI and SK On. LG Energy Solution’s Lansing plant, formerly known as Ultium Cells 3, was previously operated as a joint venture with General Motors. LGES acquired GM’s stake in May 2025 and now fully owns the site, with a production capacity of 50 GWh per year. LG Energy said the contract includes options to extend the supply period by up to seven years and boost volumes based on further consultations.
For the broader industry, the ripple effects are significant. This deal signals that domestic battery manufacturing can be financially viable and not just aspirational. Utilities, energy developers, and rival automakers will take note as American-made LFP supply becomes a competitive reality rather than a distant promise.
For consumers, the benefits will take time but are real. A more resilient, U.S.-based supply chain means fewer price shocks from trade disputes, more stable Megapack availability for the grid storage projects that reduce electricity costs, and long-term downward pressure on energy storage prices as domestic production scales.
Deliveries are set to begin in 2027 and run through mid-2030, and as grid storage demand accelerates, reliable, US-made battery supply is no longer a future ambition. It is becoming a core requirement of the country’s energy strategy.
Tesla Robotaxi appears to be heading to a new U.S. city
Tesla Roadster gets new unveiling date once again
