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Tesla patents ‘fibrous foam architecture’, hinting at new seating material and interior trim to come

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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.”

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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.

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Joey has been a journalist covering electric mobility at TESLARATI since August 2019. In his spare time, Joey is playing golf, watching MMA, or cheering on any of his favorite sports teams, including the Baltimore Ravens and Orioles, Miami Heat, Washington Capitals, and Penn State Nittany Lions. You can get in touch with joey at joey@teslarati.com. He is also on X @KlenderJoey. If you're looking for great Tesla accessories, check out shop.teslarati.com

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Tesla probe into popular Full Self-Driving feature closed by NHTSA

Actually Smart Summon allows owners to move their parked Tesla via a smartphone app remotely, directing the vehicle short distances in parking lots or private property while the driver supervises from the phone.

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tesla summon
Credit: YouTube/Hector Perez

A probe into a popular Tesla self-driving feature has been closed by the National Highway Traffic Safety Administration (NHTSA) after over a year of scrutiny from the government agency.

The NHTSA has officially closed its investigation into Tesla’s Actually Smart Summon (ASS) feature, marking a regulatory win for the electric vehicle maker after more than a year of scrutiny.

Here’s our coverage on the launch of the probe:

Tesla’s Actually Smart Summon feature under investigation by NHTSA

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The preliminary investigation, opened last January, examined roughly 2.59 million Tesla vehicles equipped with the feature across the Model S, Model X, Model 3, and Model Y lineups. ASS is not available for Cybertruck currently.

Actually Smart Summon allows owners to move their parked Tesla via a smartphone app remotely, directing the vehicle short distances in parking lots or private property while the driver supervises from the phone.

Here’s a clip of us using it:

Introduced as an upgrade to the original Smart Summon, the feature was designed to enhance convenience but drew attention after reports of low-speed incidents where vehicles bumped into stationary objects like posts, parked cars, or garage doors.

The NHTSA’s Office of Defects Investigation reviewed 159 incidents, including one formal Vehicle Owner’s Questionnaire complaint and media reports.

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Notably, all events occurred at very low speeds, resulted only in minor property damage, and involved zero injuries or fatalities. The agency determined that the incidents were “extremely rare”, a fraction of one percent across millions of Summon sessions, and did not indicate a systemic safety-related defect.

A key factor in the closure was Tesla’s proactive response through over-the-air (OTA) software updates.

During the probe, Tesla deployed at least six updates that improved camera-based object detection, enhanced neural network performance for obstacle recognition, and refined the system’s response to potential hazards. These iterative improvements, delivered wirelessly to the entire fleet, addressed the primary concerns around detection reliability and operator reaction time.

Critics of Tesla’s autonomous features had initially pointed to the crashes as evidence of rushed deployment, especially given the feature’s reliance on the company’s vision-only Full Self-Driving (FSD) stack. However, NHTSA’s decision to close the case without seeking a recall underscores the low-severity nature of the events and the effectiveness of software-based fixes in modern vehicles.

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It definitely has its flaws. I used ASS yesterday unsuccessfully:

However, improvements will come, and I’m confident in that.

The closure comes as Tesla continues to push boundaries with its autonomous driving ambitions, including unsupervised FSD rollouts and robotaxi initiatives. For owners, the ruling reinforces confidence in Actually Smart Summon as a convenient, low-risk tool rather than a hazardous experiment.

While broader NHTSA reviews of Tesla’s higher-speed FSD capabilities remain ongoing, this outcome highlights how data-driven analysis and rapid OTA remediation can satisfy regulators in the evolving landscape of automated driving technology.

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Tesla has not issued an official statement on the closure, but the move is widely viewed as bullish for the company’s autonomy roadmap, reducing one layer of regulatory overhang and allowing focus on further refinements.

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Tesla uses Model S and X ‘sentimental’ value to enforce massive pricing move

By slashing production and creating immediate scarcity, the company has transformed these remaining vehicles into limited-edition relics. The price hike is not driven by rising material costs or new features.

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Credit: Tesla

Tesla is using the “sentimental” value that CEO Elon Musk talked about with the Model S and Model X to enforce one of the most massive pricing moves it has ever applied as it begins to phase out the flagship vehicles.

Tesla quietly executed one of its most calculated pricing plays yet. After officially ending production of the Model S and Model X, the company raised prices on every remaining new and demo unit by roughly $15,000.

The refreshed starting prices now sit at:

  • $109,990 for the Model S AWD
  • $124,900 for the Model S Plaid
  • $114,900 for the Model X AWD
  • $129,900 for the Model X Plaid

Every vehicle comes fully loaded with the Luxe Package, Full Self-Driving Supervised, four years of premium connectivity and service, and lifetime free Supercharging. What looks like a simple inventory adjustment is, in reality, a masterclass in monetizing nostalgia.

These are not ordinary cars. For many owners, the Model S and Model X represent the purest expression of Tesla’s original promise—the sleek, over-engineered flagships that proved electric vehicles could be faster, quieter, and more desirable than their gasoline counterparts.

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Tesla removes Model S and X custom orders as sunset officially begins

They are the vehicles that carried Elon Musk’s vision from Silicon Valley startup to global automaker.

The final units rolling off the line carry an emotional weight that numbers alone cannot capture. Buyers are not simply purchasing transportation; they are acquiring a piece of Tesla history, the last examples of the very models that defined the brand’s first decade.

Tesla, with this move, understands this sentiment deeply.

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By slashing production and creating immediate scarcity, the company has transformed these remaining vehicles into limited-edition relics. The price hike is not driven by rising material costs or new features.

It is driven by the knowledge that a certain segment of buyers, loyalists, collectors, and enthusiasts, will pay a premium precisely because these cars are about to disappear. The strategy converts emotional attachment into margin.

Where other automakers might discount outgoing models to clear lots, Tesla is betting that sentiment is worth more than volume.

The move also quietly rewards existing owners. Scarcity instantly boosts resale values for the hundreds of thousands of Model S and X already on the road, reinforcing brand loyalty among the very people who helped build Tesla’s reputation.

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In the end, Tesla’s pricing decision reveals a sophisticated understanding of its audience. As the company pivots toward next-generation platforms, it has found a way to extract one final, lucrative chapter from its heritage.

For buyers willing to pay the new prices, the premium is not just for the car; it is for the feeling of owning the last true originals. Tesla has turned sentiment into strategy, and in the process, reminded everyone that even in the EV era, emotion remains a powerful line on the balance sheet.

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Tesla broadens most-wanted Model Y to eight new markets

This rollout targets Asia’s booming EV adoption, driven by family buyers seeking practicality without sacrificing performance or luxury. It positions Tesla against rising local competitors offering affordable three-row options.

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Credit: Tesla China

Tesla has broadened the availability of the most-wanted Model Y trim to eight new Asian markets, expanding the footprint of what is one of the most highly requested vehicle configurations in the U.S.

Tesla has officially launched ordering for the Model Y L, its long-wheelbase six-seater electric SUV, across eight key Asian territories: Japan, South Korea, Hong Kong, Macau, Singapore, Thailand, Malaysia, and the Philippines.

The announcement signals a major expansion for the family-oriented variant first introduced in China in August 2025. In Thailand, Malaysia, and the Philippines, the vehicle had already been previewed at several motor shows, so fans in the area were familiar with the Model Y L and its distinct differences to the standard-sized trims.

Local pricing reflects taxes, incentives, and import duties. Malaysia estimates RM260,000 with Q2 2026 deliveries; Singapore lists S$248,999 (including COE); Macau prices at 398,750 patacas. Similar competitive positioning is expected in Japan, South Korea, Hong Kong, Thailand, and the Philippines, where the Model Y L undercuts many traditional three-row SUVs while offering full EV benefits.

This rollout targets Asia’s booming EV adoption, driven by family buyers seeking practicality without sacrificing performance or luxury. It positions Tesla against rising local competitors offering affordable three-row options.

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Notably, the Model Y L remains unavailable in the U.S. market, where demand for a stretched Model Y has been high. Although CEO Elon Musk said that something “way cooler than a minivan” is on the way in the U.S., the dimensions of the Model Y L simply fit the needs of many American families.

Elon Musk says Tesla is developing a new vehicle: ‘Way cooler than a minivan’

The Model Y L stands out with its stretched dimensions: 4,976 mm long and a 3,040 mm wheelbase—179 mm and 150 mm longer, respectively, than the standard Model Y. Height increases slightly to 1,668 mm, creating a true three-row, 2+2+2 layout with individual captain’s chairs in the second row for easier third-row access.

Maximum cargo capacity reaches 2,539 liters with seats folded, making it ideal for growing families or those needing versatile space in dense urban environments. But it’s not just a grocery-getter or a kid-hauler: The performance matches Tesla’s reputation.

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Dual-motor all-wheel drive delivers 0-100 km/h acceleration in about 5.0 seconds (or 4.5 seconds in some market specs), with a top speed of 201 km/h. The vehicle boasts a WLTP-rated range of up to 681 km, supported by an approximately 88-97 kWh battery pack (market-dependent) and 250 kW DC fast charging.

With deliveries slated for Q2 2026 and strong early interest mirroring China’s rapid pre-orders, the Model Y L could become a bestseller in these dynamic markets. Tesla’s targeted expansion essentially generalizes its commitment to tailoring vehicles to regional needs while advancing sustainable mobility across Asia.

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