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Tesla patents ‘fibrous foam architecture’, hinting at new seating material and interior trim to come
Tesla has submitted a patent application for a “fibrous foam architecture” with claims that the manufacturing technique for seats and interior trim would create a more efficient and environmentally-sustainable process.
The submitted patent explains that the current materials used for cushioning in traditional vehicle seats include foam made from polyurethane, a material that is not able to be recycled and may not be the most comfortable due to its lack of breathability. Manufacturing the foam is also a time-consuming and laborious process that involves the pouring and mixing of numerous chemicals, like polymer or epoxy, into a mold. After setting, this requires additional material to be trimmed and shaped, thereby creating unnecessary waste that Tesla’s fibrous foam architecture hopes to eliminate.
The background of the patent states, “Trim to foam assembly may include hog ring, hook and loop, and/or clipping methods. In such methods, alignment tolerances may need to be maintained, mating surface limitations may need to be met, trenches and stitches may need to be provided and so on. Glue application storage and handling may also be required. Current manufacturing processes may be labor-intensive and time-consuming.” This would improve the production and quality of backrests, armrests, leg-rests, and bolsters.
Tesla is looking to improve upon its vehicle’s interior, as it suggests “there is a need for an improved foam architecture and associated manufacturing process that overcome the aforementioned drawbacks.”
An improved foam structure for vehicle seating will provide a new, more comfortable, recyclable material for owners of Tesla electric cars. Tesla plans to use the stacking of multiple layers of different materials to make a less-laborious and more cost-effective seating option. The use of sustainable materials that can be recycled after use will appeal to the environmentally-conscious Tesla owner. The company unveiled 100% cruelty-free seat options in 2017 to its Model S and Model X, and would later offer the 100% vegan material for the Model 3 and the upcoming Model Y.
Tesla has continued to improve its vehicles in every way imaginable for its customers through OTA power updates and accessibility features while finding efficiencies in its design and manufacturing process to support a wider scale-out in production. The company is gearing up for the initial production of the Model Y in early 2020 and the first mass-production of the Model 3 from its Shanghai-based Gigafactory 3. Tesla announced during the Q3 earnings call, “trial production of Model 3 in Shanghai has begun, ahead of schedule. We are also ahead of schedule to produce Model Y and now expect to launch by summer 2020. Model Y equipment installation is underway in advance of the planned launch next year. We are moving faster than initially planned, using learnings and efficiencies gained from our Gigafactory Shanghai factory design.”
As Tesla begins to increase the rate of production of its fleet of vehicles, efficiency is a key factor in creating a lean and cost-effective manufacturing process. Tesla is set to begin production of the Model Y crossover in 2020 and will unveil its highly-anticipated Cybertruck on November 21.
The full details of Tesla’s patent application for a “Fibrous Foam Architecture” can be viewed here.
Elon Musk
Elon Musk’s xAI wins permit for power plant supporting AI data centers
The development was reported by CNBC, citing confirmation from the Mississippi Department of Environmental Quality (MDEQ).
Mississippi regulators have approved a permit allowing Elon Musk’s artificial intelligence company xAI to construct a natural gas power plant in Southaven. The facility is expected to support the company’s expanding AI infrastructure tied to its Colossus data center operations near Memphis.
The development was reported by CNBC, citing confirmation from the Mississippi Department of Environmental Quality (MDEQ).
According to the report, regulators “voted to approve the permit” of xAI subsidiary MZX Tech LLC to construct a power plant featuring 41 natural gas-burning turbines “after careful consideration of all public comments and community concerns.”
The Mississippi Department of Environmental Quality stated that the permit followed a regulatory review process that included public comments and community input. Jaricus Whitlock, air division chief for the MDEQ, stated that the project met all applicable environmental standards.
“The proposed PSD permit in front of the board today not only meets all state and federal permitting regulations, but goes above and beyond what is required by law. MDEQ and the EPA agree that not a single person around our facilities will be exposed to unhealthy levels of air pollution,” Whitlock stated.
The planned facility will help provide electricity for xAI’s AI computing infrastructure in the Memphis region.
The Southaven project forms part of xAI’s efforts to scale computing capacity for its artificial intelligence systems.
The company currently operates two major data centers in Memphis, known as Colossus 1 and Colossus 2, which provide computing power for xAI’s Grok AI models. xAI is also planning to build another large data center in Southaven called Macrohardrr, which would be located in a warehouse previously used by GXO Logistics.
Large-scale AI training requires substantial computing power and electricity, prompting technology companies to develop dedicated energy infrastructure for their data centers.
SpaceX President Gwynne Shotwell previously stated that xAI plans to develop 1.2 gigawatts of power capacity for its Memphis-area AI supercomputer site as part of the federal government’s Ratepayer Protection Pledge. The commitment was announced during an event with United States President Donald Trump.
“As part of today’s commitment, we will take extensive additional steps to continue to reduce the costs of electricity for our neighbors. xAI will therefore commit to develop 1.2 GW of power as our supercomputer’s primary power source. That will be for every additional data center as well. We will expand what is already the largest global Megapack power installation in the world,” Shotwell said.
“The installation will provide enough backup power to power the city of Memphis, and more than sufficient energy to power the town of Southaven, Mississippi where the data center resides. We will build new substations and invest in electrical infrastructure to provide stability to the area’s grid.”
Elon Musk
Tesla China teases Optimus robot’s human-looking next-gen hands
The image was shared by Tesla AI’s account on Weibo and later reposted by Tesla community members on X.
A new teaser shared by Tesla’s China team appears to show a pair of unusually human-like hands for Optimus.
The image was shared by Tesla AI’s account on Weibo and later reposted by Tesla community members on X.
As could be seen in the teaser image, the new version of Optimus’ hands features proportions and finger structures that look strikingly similar to those of a human hand. Their appearance suggests that they might have dexterity approaching that of a human hand.
If the image reflects a new generation of Optimus’ hands, it could indicate Tesla is continuing to refine one of the most critical components of its humanoid robot.
Hands are widely viewed as one of the most difficult engineering challenges in robotics. For Optimus to perform complex real-world work, from manufacturing tasks to household activities, its hands would need to be the best in the industry.
Elon Musk has repeatedly described Optimus as Tesla’s most important long-term product. In posts on social media platform X, Musk has stated that Optimus could eventually become the first real-world Von Neumann machine.
In theory, a Von Neumann machine is a self-replicating system capable of building copies of itself using available materials. The concept was originally proposed by mathematician John von Neumann in the mid-20th century.
“Optimus will be the first Von Neumann machine, capable of building civilization by itself on any viable planet,” Musk wrote in a post on X.
If Optimus is expected to carry out complex work autonomously in the future, high levels of dexterity will likely be essential. This makes the development of advanced robotic hands a key step towards Musk’s long-term expectations for the product.
News
Tesla Cybercab ramps Robotaxi public street testing as vehicle enters mass production queue
Recent sightings on public roads and growing fleet activity at Giga Texas signal Tesla’s accelerating push toward the Cybercab’s commercial launch.
Tesla Cybercab is being spotted with increasing frequency both on public roads and across the grounds of Gigafactory Texas, suggesting that the company’s road testing and validation program is ramping meaningfully ahead of mass production.
A total of 25 Cybercab units were recently observed across three separate locations at Giga Texas by drone observer Joe Tegtmeyer — with 14 metallic gold units parked in a tight formation outside the factory exit, nine more at the crash testing facility undergoing structural and safety validations, and two additional units at the west end-of-line area for final checks.
The activity on public roads is just as telling. The Cybercab was spotted testing on public roads for the first time last October, near Tesla’s Engineering Headquarters in Los Altos, California, marking a significant development in the vehicle’s progression toward commercial readiness. As expected at that early stage, a safety driver was present in the seat.
Since then, sightings have only become more frequent. Community observers on X have posted fresh footage of Cybercabs navigating public streets in Silicon Valley, with each new clip adding to a growing body of evidence that Tesla’s validation efforts are well underway. The production backdrop supports the momentum. Tesla’s production line at Giga Texas moved into a higher volume early in March, representing what observers are calling the largest single-day grouping of Cybercabs seen to date.
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- Tesla Cybercab spotted in San Jose, CA testing on public roads with Robotaxi validation equipment [Credit: Nic Cruz Patane via X]
![Tesla Cybercab spotted testing on public roads in Los Gatos, CA - March 10, 2026 [Credit: Osmad Sarood via X]](https://www.teslarati.com/wp-content/uploads/2026/03/tesla-cybercab-public-road-testing-823x1024.jpg)
Tesla Cybercab spotted testing on public roads in Los Gatos, CA – March 10, 2026 [Credit: Osman Sarood via X]
Tesla ramps Cybercab test manufacturing ahead of mass production
Musk has also stated that Tesla is aiming for at least 2 million Cybercab units per year across more than one factory, with a potential ceiling of 4 million annually.
With testing activity on public roads accelerating and factory output visibly increasing week over week, the coming months at Giga Texas are set to be pivotal in determining how quickly Tesla can bring the Cybercab from validation to volume.
Elon Musk’s xAI wins permit for power plant supporting AI data centers
Tesla China teases Optimus robot’s human-looking next-gen hands
