Investor's Corner
Tesla patents aluminum “spray quench” process for molecular-level strengthening
Tesla has submitted a patent that describes a new, more effective cooling process for manufacturing high-strength aluminum components to be used in its product line.
The patent entitled, “System and Method for Facilitating Pulsed Spray Quench of Extruded Objects”, describes a quenching process that aims to increase the strength, rigidity, and energy absorption of aluminum alloy components. A multi-way spray nozzle system would cool extruded aluminum with an atomized spray of liquid.
“A system includes a billet die at a proximal end configured to accept a billet and form an extrudate, a quench chamber located adjacent to the billet die for receiving the extrudate and comprising at least one pulsed width modulation (PWM) atomizing spray nozzle and a control module in communication with the at least one PWM atomizing spray nozzle and configured to independently control a liquid pressure, a gas pressure, a spray frequency, a duty cycle and flow rate of each at least one PWM atomizing spray nozzle,” reads the patent abstract.
Vehicles today use 6XXX aluminum alloys, which make up the front and rear bumpers, side and back steps, and knee bolsters of a car, the Kobelco Technology Review stated. Tesla also indicates within the patent that it uses 6XXX alloys for its vehicles. After these parts are extruded, they enter a quenching process, which is simply the process of cooling the metal after it has been heated.
Currently, Tesla utilizes a quenching process that involves cooling recently extruded aluminum alloys by soaking the parts in water. This process of quenching is recognized as “quick cooling.” While other cooling means are available, such as air cooling and furnace cooling, soaking the parts in water is the most time-effective method for automotive manufacturing.
However, Tesla’s patent recognizes the adverse effects that quick cooling aluminum alloy parts can have on the structural integrity of the metal. Quick-cooling can not only lead to deformation and warping of metal parts, but things can change chemically as well.
Magnesium silicide, or Mg2Si, is present in these aluminum alloy parts, and quick cooling them can inhibit the compound’s ability to set in the metal. Without the proper setting of Mg2Si by quick-cooling the aluminum alloy in water, the metal requires a higher extrusion pressure and becomes more sensitive to heat, according to Light Metals 2014. The combination of these two properties can effectively compromise the mechanical properties of the final product, making the frame of the vehicle lose strength through the manufacturing process.
Tesla plans to utilize a multi-way spraying system to cool extruded aluminum parts, eliminating the soaking process that is used by so many manufacturers of aluminum alloy. In the patent, the company describes a quenching system that would spray newly extruded metals at varying rates depending on the size of the part. Between one half-gallon and 10 gallons of water per minute would cool the metal in question.
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- Tesla’s described cooling process. (Credit: U.S. Patent Office)
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- Tesla’s described cooling process. (Credit: U.S. Patent Office)
Two pyrometers would be placed at both the proximal and distal ends of the quench chamber. These would hold the responsibility of maintaining the metal’s temperature through the quenching process. The pyrometers would communicate with the system to ensure proper cooling temperatures, making sure the aluminum does not cool too quickly, allowing the Mg2Si to set. In conjunction with the temperature control, spray frequency, liquid pressure, gas pressure, and flow rate will also be monitored to ensure maximum strength after extradition is complete.
Tesla’s recognition of the flaws in quick-cooling extruded metals indicates the company’s realization that increased strength of a car’s frame could improve with a more efficient cooling technique.
In the teardown of the Model Y, Sandy Munro complimented Tesla’s use of what he called the “aluminum rear crush plate.” The piece is located at the trunk hatch and is designed to fold in the event of a rear-impact. The part saves the sides of the body from being compromised in a crash, which can ultimately total the vehicle if the chassis bends excessively.
While the crush plate is durable and prevents excessive damage to the body of the Model Y, the quick-cooling process used during manufacturing could ultimately make the crush plate less sustainable than what it could be. Not to mention, the front bumper, rear bumper, side and back steps, and knee bolsters are also made of aluminum. Using a different cooling technique could eventually lead to an even safer Tesla vehicle, which already has many five-star crash safety ratings from several organizations located around the world.
Read Tesla’s patent for a new aluminum cooling process below.
Tesla SYSTEM AND METHOD FOR FACILITATING PULSED SPRAY QUENCH OF EXTRUDED OBJECTS by Joey Klender on Scribd
Tesla (NASDAQ: TSLA) is set to hold its Earnings Call for the first quarter of 2026 on Wednesday, and there are a lot of interesting things that are swirling around in terms of speculation from investors.
With the company’s executives, including CEO Elon Musk, answering a handful of questions that investors submit through the Say platform, fans want to know a lot of things about a lot of things.
These five questions come from Retail Investors, who are normal, everyday shareholders:
- When will we have the Optimus v3 reveal? When will Optimus production start, since we ended the Model S and Model X production earlier than mid-year? What’s the expected Optimus production rate exiting this year? What are the initial targeted skills?
- What milestones are you targeting for unsupervised FSD and Robotaxi expansion beyond Austin this year, and how will that drive recurring revenue?
- How will Hardware 3 cars reach Unsupervised Full Self-Driving?
- When do you expect Unsupervised Full Self-Driving to reach customer cars?
- When will Robotaxi expand past its current limited rollout?
Additionally, these are currently the three questions that are slated to be answered by Institutional Firms, which also answer a handful of questions during the call:
- Now that FSD has been approved in the Netherlands and is expected to launch across Europe this summer, can you discuss your Robotaxi strategy for the region?
- What enabled you to finish the AI5 tapeout early and were there any changes to the original vision? Last week, Elon said AI5 will go into Optimus and the Supercomputer, but one month ago said it would go into the Robotaxi. Has AI5 been dropped from the vehicle roadmap?
- Given the recent NHTSA incident filings, can you update us on the Robotaxi safety data? If safety validation remains the primary bottleneck, why not deploy thousands of vehicles to accelerate the removal of the safety driver?
The questions range through every current Tesla project, including FSD expansion and Optimus. However, many of the answers we will get will likely be repetitive answers we’ve heard in the past.
This is especially pertinent when the questions about when Unsupervised FSD will reach customer cars: we know Musk will say that it will happen this year. Is Tesla capable of that? Maybe. But a more transparent answer that is more revealing of a true timeline would be appreciated.
Hardware 3 owners are anxiously awaiting the arrival of FSD v14 Lite, which was promised to them last year for a release sometime this year.
The Earnings Call is set to take place on Wednesday at market close.
Elon Musk
Tesla FSD in Europe vs. US: It’s not what you think
Tesla FSD is approved in the Netherlands, but the European version differs from what US drivers use.
On April 10, 2026, the Dutch vehicle authority RDW granted Tesla the first European type approval for Full Self-Driving Supervised, making the Netherlands the first country on the continent to authorize Tesla’s semi-autonomous system for customer use on public roads.
As Teslarati reported, the RDW approval followed 18 months of testing, more than 1.6 million kilometers driven on EU roads, 13,000 customer ride-alongs, and documentation covering over 400 compliance requirements. Tesla Europe had been running public demo drives through cities like Amsterdam and Eindhoven since early 2026, giving passengers their first experience of the system on European streets.
The European version of FSD is not the same software US drivers use. The RDW’s own statement is direct, noting that the software versions and functionalities in the US and Europe “are therefore not comparable one-to-one.” We’ve compile a table below that captures the most significant differences between US-based Tesla FSD vs. European Tesla FSD that’s based on what regulators and Tesla have publicly confirmed.
| Feature | FSD US | FSD Europe (Netherlands) |
| Regulatory framework | Self-certification, post-market oversight | Pre-market type approval required (UN R-171 + Article 39) |
| Hands requirement | Hands-off permitted on highway | Hands must be available to take over immediately |
| Auto turning from stop lights | Available — navigates intersections, turns, and traffic signals autonomously | Available in EU build — confirmed in Amsterdam demo footage handling unprotected turns and signalized intersections |
| Driving modes | Multiple profiles including a more aggressive “Mad Max” mode | EU build is more conservative by default and errs on the side of restraint when it cannot confirm the limit |
| Summon | Available — Smart Summon navigates parking lots to driver | Status unclear — not confirmed as part of the RDW-approved feature set; urban FSD approval targeted separately for 2027 |
| Driver monitoring | Camera-based eye tracking | Stricter continuous monitoring with more frequent intervention alerts |
| Software version | FSD v14.3 | EU-specific builds that must be separately validated by RDW |
| Geographic restriction | US, Canada, China, Mexico, Australia, NZ, South Korea | Netherlands only; EU-wide vote pending summer 2026 |
| Subscription price | $99/month | €99/month |
| Full urban FSD scope | Available | Partial — separate urban application planned for 2027 |
The approval comes as Tesla is under real pressure to grow FSD subscriptions globally. Musk’s 2025 CEO compensation package, approved by shareholders, includes a milestone requiring 10 million active FSD subscriptions as one condition for his stock awards to vest. Tesla hit one million subscriptions during its Q4 2025 earnings call, which is a meaningful start, but still a long way from the target. Opening Europe as a market for subscriptions, rather than just hardware sales, directly accelerates that number.
Tesla has said it anticipates EU-wide recognition of the Dutch approval during summer 2026, which would extend FSD access to Germany, France, and other major markets through a mutual recognition process without each country repeating the full 18-month review. That timeline is Tesla’s projection, not a confirmed regulatory outcome. As Musk acknowledged at Davos in January 2026, “We hope to get Supervised Full Self-Driving approval in Europe, hopefully next month.”
Elon Musk
Tesla Supercharger for Business exposes jaw-dropping ROI gap between best and worst locations
Tesla’s new Supercharger for Business calculator reveals an eye-opening all-in cost and location-based ROI projections.
Tesla has launched an online calculator for its Supercharger for Business program, giving property owners their first transparent look at what it really costs to install Superchargers on site and what kind of return they can expect.
The program itself launched in September 2025, allowing businesses to purchase and operate Supercharger hardware on their own property while Tesla handles installation, maintenance, software, and 24/7 driver support. As Teslarati reported at launch, hosts also get their logo placed on the chargers and their location integrated into Tesla’s in-car navigation, meaning drivers are actively routed there. The stalls are open to all EVs, not just Teslas.
We launched Supercharger for Business in 2025 to help companies get charging right. We found simplicity and transparency to be a problem in this industry.
We’re now sharing pricing and a financial calculator to help make informed decisions. The goal is to accelerate investments,…
— Tesla Charging (@TeslaCharging) April 8, 2026
The new online calculator, announced by Tesla on Wednesday with the note that “simplicity and transparency” have been a problem in the industry, lets any business enter a U.S. address and get a real cost and revenue model. A standard 8-stall V4 Supercharger site runs approximately $500,000 in hardware and $55,000 per post for installation, bringing an all-in price just shy of $1 million. Tesla charges a flat $0.10 per kWh fee to cover software, billing, and network operations. Businesses set their own retail price and keep the margin above that fee.
Taking a look at Tesla’s Supercharger for Business online calculator, we can see that ROI is not uniform, and the gap between a strong location and a poor one can stretch the breakeven point by several years.
The biggest driver is foot traffic and how long people stay. A busy rest station, hotel, or outlet mall brings in repeat visitors who need to charge while they’re already stopped, pushing utilization numbers higher and shortening payback time.
Tesla Supercharger for Business ROI calculator
Local electricity rates matter just as much on the cost side. Markets like California carry some of the highest commercial electricity rates in the country, which eats into the margin between what a host pays per kWh and what they charge drivers. At the same time, dense urban areas with high EV adoption tend to support higher retail charging prices, which can offset that cost if demand is strong enough. Weather also plays a role. Cold climates reduce battery efficiency and increase charging frequency, but they can also suppress utilization in winter months if drivers avoid stopping in exposed outdoor locations. Suburban and rural sites face a different problem: lower baseline EV traffic, which means a site with cheaper power and lower operating costs can still take longer to pay back simply because the stalls sit idle more often. Tesla’s calculator uses real fleet data to pre-fill utilization estimates by ZIP code, so businesses can run their specific address against these variables rather than relying on averages.
The program has seen real adoption. Wawa, already the largest host of Tesla Superchargers with over 2,100 stalls across 223 locations, opened its first fully owned and branded site in Alachua, Florida earlier this year. Francis Energy of Oklahoma and the city of Alpharetta, Georgia have also deployed branded stations through the program, as Teslarati covered in January.
Tesla now exceeds 80,000 Supercharger stalls worldwide, and the calculator makes the economic case for accelerating that number through private investment rather than company-owned sites alone.
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