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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.
Tesla has reportedly pushed the unveiling of the Roadster once again, but there are also evidently new details about the event that the company plans to show off.
The Information reported this morning that Tesla will now unveil, for the second time, the next-generation Roadster in August, a further delay from the multiple timeline that the company had previously stated.
The report has not been confirmed or denied by Tesla at any capacity.
It also states the unveiling event will take place in Texas, the same place that Tesla executives revealed in May would be the place of manufacture for the company’s highly-anticipated supercar, which boasts a top speed of over 250 MPH and 650 miles of range, according to its website.
Tesla is also expected to showcase the SpaceX package, which will be used for faster acceleration and potentially hovering capabilities, at the unveiling event, the report states. Musk has always planned for this to happen, but now it seems it is more realistic than ever
The report also states the Roadster unveiling is planned for August pic.twitter.com/By26XZIJzU
— TESLARATI (@Teslarati) June 5, 2026
The Roadster has had its unveiling date and manufacturing date pushed back on many occasions. It was set to start production in 2020, but the COVID-19 pandemic crippled supply chain operations, forcing Tesla to push its timeline back considerably.
However, COVID has been over for some time, and Tesla has still not managed to successfully schedule and execute an unveiling event, which is something fans and enthusiasts, as well as those who have put down a $50,000 deposit, have been waiting for.
The vehicle was close to completion last year, but Musk truly wanted Lars Moravy and Franz von Holzhausen to push the limits of the Roadster. In July of last year, Moravy said:
“Roadster is definitely in development. We did talk about it last Sunday night. We are gearing up for a super cool demo. It’s going to be mind-blowing; We showed Elon some cool demos last week of the tech we’ve been working on, and he got a little excited.”
It is important to note two things: Tesla has not confirmed these details, and the company has regularly pushed these dates back. Until Tesla sends out formal invitations with a concrete date, taking any unveiling event reports with a grain of salt is a good idea.
Tesla is offering a tasty Supercharging incentive on certain Model 3 trims, but the company has officially put a concrete end date on it, so those interested should act fast.
Tesla is offering Free Supercharging for One Year on the Model 3 Premium and Performance trims, the top two offerings of the all-electric sedan. There are three trims of the Model 3 that will have the Free Supercharging offer attached:
- Premium Rear-Wheel-Drive – $42,490
- Premium All-Wheel-Drive – $47,490
- Performance – $54,990
Tesla has now announced that this offer will expire on June 15, giving potential buyers about ten days to take advantage of the incentive.
This could be an additional incentive for car buyers to transition to electric vehicles. Many states are showing gas prices well over $4 per gallon, with the national average currently sitting at $4.22, according to AAA.
A free year of Supercharging miles would allow people to charge and travel for free, other than routine maintenance, which is already incredibly cheap compared to a gas car.
🚨 Tesla is now showing that it’s Free Supercharging offer for Model 3 Premium and Performance trims ends June 15 pic.twitter.com/VCLeddNSj8
— TESLARATI (@Teslarati) June 5, 2026
At Tesla Superchargers, peak rates, meaning prices between 8 a.m. and 10 p.m., average between $0.45 and $0.60. One year of driving at an average of 12,000 miles would cost between $1,000 and $1,500 at $0.50 per kWh. It’s a pretty good deal.
Supercharging prices have also increased recently:
Many of the Superchargers in my area just had their peak rates increased from $0.44 per kWh to $0.49, $0.52, and $0.54 per kWh
If you’re looking to save on your commute/travel for the next year, this Model 3 Free Supercharging incentive might not be a bad idea https://t.co/YDwwl4xxHk pic.twitter.com/DleURW7eqa
— TESLARATI (@Teslarati) June 5, 2026
Tesla has used Free Supercharging to move units in the past, and it’s a great strategy for those who plan to use the car for longer commutes, cross-country drives, or do not have reliable access to home charging.
It should be noted that Tesla recommends that Supercharging be used at a minimum to preserve the life of the battery, as fast-charging is more stressful on the cells.
However, some people might not have an option, so the Free Supercharging incentive could truly be a great reason for many people to charge their cars.
The Supercharging incentive is short-term, and it is pretty rare that Tesla utilizes it, so once this offer is gone, we probably will not see it on the Model 3 for some time.
Ferrari CEO Benedetto Vigna revealed that the Italian automaker’s future will not involve self-driving, a point that echoes that of Tesla CEO Elon Musk’s — sort of.
You might be thinking, “Are you insane? Musk has been so incredibly hellbent on delivering self-driving vehicles to the public, so much so that he has even hinted that Tesla won’t need the ever-popular and widely-requested Model Y L in the U.S.”
However, when it comes to electric supercars with high-performance specs and lofty price tags, Vigna’s stance is exactly what Musk wants for Tesla’s own hypercar project, the Tesla Roadster.
🚨 Tesla Roadster vs. Ferrari Luce
Price – $250,000 vs. $640,000
Horsepower – 1,000+ vs. 1,035
0-60 MPH – 1.1s OR 1.9s vs. 2.4s
Top Speed – 250+ MPH vs. 194 MPH
Range – 620 miles vs. 280 miles https://t.co/uEgswwVLeD pic.twitter.com/XcP58ZRO6Z— TESLARATI (@Teslarati) June 5, 2026
In a new interview with Australian media outlet Drive, Vigna made it clear that Ferrari’s ambitions for the future do not involve autonomy, simply because the company’s cars are not designed for anything but manual, spirited driving.
He said:
“We will not make fully autonomous cars — loud and clear. We want the people to have fun, not the [computer] chips. We want to have a steering wheel and a man or a woman behind the steering wheel. Otherwise, why do you buy a Ferrari?”
This seems to be a reasonable assertion. Ferraris are not made for daily commutes, cross-country road trips, or bumper-to-bumper traffic. They’re made for fast, spirited driving, and many of their buyers will only put a few thousand miles on them throughout their lifetime. True, exciting, fun driving is meant to be done manually.
That is not to say Full Self-Driving or other semi-autonomous suites are not “fun,” but they are meant to take the stress out of driving. They are made for the daily commutes, the rush hour traffic, and the parking lots and garages. It’s made to take the stress out of driving.
Tesla Full Self-Driving attempts 150-mile stress test: the good and the bad
Musk had stated in an interview in early 2026 that the Roadster would also be geared toward fun, manually-controlled driving. On the Moonshots podcast with Peter Diamandis, Musk said about the Roadster:
“This is not a…safety is not the main goal. If you buy a Ferrari, safety is not the number one goal. I say, if safety is your number one goal, do not buy the Roadster…We’ll aspire not to kill anyone in this car. It’ll be the best of the last of the human-driven cars. The best of the last.”
There are cars out there that simply are meant to be driven by humans, and Ferraris and Roadsters are a few of them. Ferrari has no true advantage in developing self-driving; their cars sell at low volumes with high price tags, and their performance specs and engineering are all geared toward spirited driving.
Tesla Roadster unveiling gets pushed again, but new event details emerge
Tesla Model 3 has a tasty Supercharging incentive, but it’s ending soon
