News
Tesla patent addresses panel gaps using clever clamping assembly
The build quality of Tesla’s vehicles would likely see a notable improvement in the near future. As revealed in a recently published patent, the company is working on a new type of clamping assembly that allows some flexibility between panels during manufacturing. With such a system in place, gaps between a vehicle’s panels could be adjusted and aligned during the assembly process.
Tesla’s newly published patent, titled “Clamping Assembly for Securing Together a Pair of Adjacently Located Panels,” describes a simple yet clever way to address misaligned body panels. Tesla notes that conventional clamps, which are usually utilized to attach body panels to a vehicle’s frame, are unable to connect panels and their individual tolerances effectively due to their rigid structure.
“Although (conventional clamps) can be used to secure adjacently located parts to one another, the clamp does not account for parts that have large manufacturing tolerances or parts that must not be fixed in at least one direction (that is there must be play between the parts). Attempting to use a traditional clamp to secure two parts that must have some play between them may introduce unsightly gaps and/or overlaps between the parts, reducing the aesthetic appearance upon assembly.”
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- [Credit: US Patent Office]
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Diagrams depicting Tesla’s design for its new clamping assembly. [Credit: US Patent Office]
Tesla’s patent outlines a new type of clamping assembly that is more flexible. Such a system enables Tesla to adjust panels during assembly, allowing the company to address any possible misaligned panels before the vehicle is sent off to delivery. Tesla explains the rationale of its new clamp as follows.
“The present invention was derived in light of the foregoing challenges, and it is an object of the present invention to provide a clamping assembly that provides flexibility in securing parts that are manufactured to larger dimensional tolerances and in which play is necessary between adjacent parts during, or after, assembly. The clamping assembly of the present invention can accommodate misalignment of the part or parts owing to variances in one or both parts during manufacture and/or necessary play between the parts by allowing flexibility in adjusting the positions of the parts relative to one another in one direction while still securing the parts to one another. That is, the clamping assembly secures together a pair of manufactured parts, in which the manufactured parts require play along at least one direction while confining the movement of the parts in a second direction.
“According to certain embodiments of the present invention, the clamping assembly includes a retainer member. The retainer member may have a U-shape groove that allows for the insertion of a tab member and a narrow retaining throat that confines a bulbous portion of the tab member in multiple directions. For example, once inserted into the groove of the retainer member, the tab member with the bulbous portion is confined from moving vertically and horizontally. Once inserted into the groove of the retainer member, movement of the tab member with the bulbous portion is possible by sliding the tab member and the bulbous portion thereof relative to a plane P 2 of the groove, i.e., by sliding the tab member and the bulbous portion into or out of the page. Thus, with use of the clamping assembly disclosed herein, some play or flexibility between two panels is possible, and the panels can be adjusted relative to one another during assembly.”
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- [Credit: US Patent Office]
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- [Credit: US Patent Office]
Diagrams depicting Tesla’s design for its new clamping assembly. [Credit: US Patent Office]
Tesla has been challenged with misaligned panels on its vehicles in the past. When Detroit’s Sandy Munro started his teardown of an early production Model 3, for one, the auto veteran lamented that the vehicle’s panel gaps were so inconsistent, they were reminiscent of a Kia from the 90s. Munro was eventually blown away by the Model 3’s battery, tech, ride quality, and performance, but his criticism of the car’s build quality were notable until he completed his analysis. Tesla later issued a response to Munro’s criticism of the early production Model 3’s build quality, stating that “the standard deviation of all gaps and offsets across the entire car has improved, on average, by nearly 40%, with particular gap improvements visible in the area of the trunk, rear lamps and rear quarter panel.”
A letter to Tesla employees sent last April revealed that Elon Musk is taking the issue of misaligned panels very seriously. In his message, Musk noted that while the build quality of the company’s vehicles continues to improve, Tesla must strive to push harder in ensuring that its electric cars have design tolerances that are a factor of ten better than any other vehicle in the auto industry.
“Most of the design tolerances of the Model 3 are already better than any other car in the world. Soon, they will all be better. This is not enough. We will keep going until the Model 3 build precision is a factor of ten better than any other car in the world. I am not kidding. Our car needs to be designed and built with such accuracy and precision that, if an owner measures dimensions, panel gaps, and flushness, and their measurements don’t match the Model 3 specs, it just means that their measuring tape is wrong,” Musk wrote.
There is no denying that misaligned panels are an issue for Tesla’s electric cars, particularly early production models produced in the past. In a way, such issues are part of Tesla’s growing pains, considering that mastering panel alignment is among the more basic aspects of vehicle manufacturing. That said, Elon Musk’s unrelenting stance on improving build quality, together with clever ways to address and avoid misaligned panels, might soon allow the company to shake off its panel gap issues altogether.
Investor's Corner
Tesla Optimus is already benefiting investors, top Wall Street firm says
Piper Sandler has updated its detailed valuation model for Tesla (NASDAQ: TSLA), concluding that at recent share prices around $400–$420, investors are essentially acquiring the company’s ambitious Optimus humanoid robot project at no extra cost.
Tesla Optimus is already benefiting investors from a fiscal standpoint, at least that is what Alexander Potter at Piper Sandler, a top Wall Street firm covering the company, says.
Piper Sandler has updated its detailed valuation model for Tesla (NASDAQ: TSLA), concluding that at recent share prices around $400–$420, investors are essentially acquiring the company’s ambitious Optimus humanoid robot project at no extra cost.
Analyst Alexander Potter, in the firm’s latest “Definitive Guide to Investing in Tesla,” built a comprehensive framework covering 17 separate product lines.
This granular approach values Tesla’s core businesses—including electric vehicles, energy storage, Full Self-Driving (FSD) software, in-house insurance, Supercharging network, and a standalone robotaxi operation—at approximately $400 per share, without assigning any value to Optimus or related inference-as-a-service opportunities.
“At $400/share, we think investors can buy Optimus for ‘free,’” Potter stated in the note. Piper Sandler maintained its Overweight rating on Tesla shares and a $500 price target, which implicitly attributes roughly $100 per share to the robot-related businesses— a figure the analyst views as potentially conservative.
The updated model incorporates elements often overlooked by other sell-side analysts, such as detailed forecasts for Tesla’s insurance operations, Supercharger revenue, and a distinct valuation for the robotaxi business separate from FSD software licensing. It also accounts for Tesla’s 2025 CEO compensation plan for the first time.
Potter acknowledged that his estimates for 2026 and 2027 fall below Wall Street consensus, citing factors like declining deliveries from certain discontinued models and reduced regulatory credit income.
However, he expressed limited concern, noting that traditional vehicle delivery metrics are expected to matter less over time as FSD subscriber growth and robotaxi deployment metrics gain prominence. On Optimus specifically, Potter suggested the humanoid robot program, combined with inference services, “arguably will be worth more than Tesla’s other businesses combined,” though the firm has not yet produced formal long-term forecasts for these segments.
Tesla shares have traded near the $400 range in recent sessions, reflecting ongoing investor focus on the company’s autonomous driving progress and expansion into robotics and AI. The Optimus project remains in early development stages, with Tesla aiming to deploy the robots initially for internal factory tasks before broader commercial applications.
This Piper Sandler analysis highlights the growing emphasis among some investors and analysts on Tesla’s long-term technology platform potential beyond its current automotive and energy businesses.
As with any forward-looking valuation, outcomes will depend on execution timelines, technological breakthroughs, regulatory approvals for autonomous systems, and market adoption of humanoid robotics—areas that carry significant uncertainty and execution risk.
The note underscores a common theme in Tesla coverage: differing views on how to quantify emerging high-growth opportunities like robotics within the company’s overall enterprise value. Investors are advised to consider their own risk tolerance and conduct thorough due diligence regarding these speculative elements.
News
Tesla Giga Texas buzzing as new Cybertruck appears to enter production
Additionally, the Cybercab manufacturing ramp-up is continuing amidst Tesla’s busy May, which includes a handful of things from an automotive perspective.
Tesla Giga Texas is buzzing with a lot of action, as it appears the new Cybertruck trim that was offered a few months back has entered production. Additionally, the Cybercab manufacturing ramp-up is continuing amidst Tesla’s busy May, which includes a handful of things from an automotive perspective.
Drone operator Joe Tegtmeyer captured striking footage over Giga Texas on the morning of May 11, 2026, revealing fresh batches of Cybertrucks that may mark the start of series production for the long-awaited $59,990 Dual Motor AWD variant.
Tesla launches new Cybertruck trim with more features than ever for a low price
The vehicles lined up in staging areas, and we got a great look at three of the units parked on the property:
Hard to say for sure, but production of the $59K AWD @Cybertruck may be just getting started here on this early and soggy morning at Giga Texas … this version is much harder to visually distinguish from the premium AWD versions, so I’ll come back on Wednesday and we’ll see if… pic.twitter.com/UX7yCQpgeC
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) May 11, 2026
Tegtmeyer notes the difficulty in visually distinguishing this base AWD model from higher-trim versions, unlike the earlier Long-Range RWD that lacked a motorized tonneau cover.
Tesla launched the $59,990 Dual Motor AWD Cybertruck in late February 2026 with a brief introductory pricing window that closed by month’s end.
Initial U.S. delivery estimates of June 2026 quickly slipped to September–October and, for newer orders, as far as April 2027.
The move underscores robust consumer interest in a more accessible all-wheel-drive Cybertruck priced under $60,000 before incentives—positioning it as a volume play for Tesla’s electric pickup lineup while premium AWD and Cyberbeast variants continue to be sold as usual.
Meanwhile, Cybercab production at the same Austin facility shows steady, if deliberate, progress. Tegtmeyer’s latest flyover documented dozens of glossy production-spec Cybercabs parked in the outbound lot—consistent with Tesla’s early statements that initial output would remain modest before scaling later in 2026.
The purpose-built robotaxi, unveiled in 2024 and lacking a steering wheel or pedals, rolled its first unit off the line in February. Volume manufacturing began in April, with early examples already undergoing autonomous testing around the factory grounds.
Elon Musk has repeatedly emphasized that Cybercab and Semi production will start slowly before ramping “exponentially” toward year-end. The presence of multiple finished units signals Tesla’s Unboxed manufacturing process is maturing, even as the company balances Cybertruck output with autonomy milestones.
Recent drone imagery also shows ongoing construction for Optimus and test-track expansions, highlighting Giga Texas’s evolving role as Tesla’s hub for next-generation vehicles.
For Cybertruck buyers, the potential ramp of the $59K AWD offers hope of shorter waits and broader market access. For autonomy enthusiasts, the growing fleet of Cybercabs hints at robotaxi service trials on the horizon.
While official confirmation from Tesla remains pending, Tegtmeyer’s footage provides the clearest public signal yet that both programs are advancing in parallel at Giga Texas.
News
Tesla Full Self-Driving gains momentum in Europe with new country mulling approval
Tesla is advancing FSD’s technology across Europe with fresh talks underway in Ireland, signaling broader regulatory progress. On May 10, Ireland’s Department of Transport confirmed that Tesla is actively engaging with national authorities, including the National Standards Authority of Ireland (NSAI) to secure approval for FSD Supervised.
Tesla Full Self Driving (FSD) technology is gaining momentum in Europe, with yet another new country mulling a potential approval for operation on its roads.
Tesla is advancing FSD’s technology across Europe with fresh talks underway in Ireland, signaling broader regulatory progress. On May 10, Ireland’s Department of Transport confirmed that Tesla is actively engaging with national authorities, including the National Standards Authority of Ireland (NSAI) to secure approval for FSD Supervised.
While the department noted that full rollout in Ireland would ultimately depend on EU-level clearance, the engagement marks a notable step forward in Tesla’s European expansion strategy, Irish media outlet RTE said.
The news comes on the heels of a landmark breakthrough in the Netherlands. In April, Dutch vehicle authority RDW granted the first-ever EU type approval for FSD Supervised after 18 months of rigorous testing on public roads and tracks. The provisional approval allows the system on all Dutch roads, with Tesla already rolling it out to select owners following mandatory safety training.
The Netherlands has since notified the European Commission and is advocating for wider recognition, positioning the Dutch decision as a potential template for the bloc.
Europe has long lagged behind the United States, China, and other markets where FSD is more widely available. Strict EU regulations on automated driving systems have required extensive validation, but momentum is building.
Tesla now lists the Netherlands alongside established markets such as the U.S., Canada, Australia, and South Korea on its regional FSD page. Other countries, including Belgium, are reportedly fast-tracking their own review processes in response to the Dutch precedent.
Analysts see Ireland’s involvement as strategic. As a smaller EU member with unique road challenges—narrow rural lanes, hedgerows, and variable weather—successful validation there could demonstrate FSD’s adaptability and strengthen the case for harmonized EU approval.
Tesla has indicated it aims for broader EU deployment as early as summer 2026, though the timeline remains fluid. Discussions at the EU’s Technical Committee on Motor Vehicles continue, with a possible vote later in the year. Some member states, particularly in Scandinavia, have expressed reservations over edge cases like speeding protocols and long-term safety data.
For Tesla, European expansion is more than a software update; it unlocks significant growth. The continent’s dense population and high vehicle ownership could accelerate data collection, refine the AI models powering FSD, and pave the way for unsupervised autonomy and robotaxi services.
Owners stand to benefit from enhanced safety features and reduced driver fatigue, while regulators weigh innovation against proven risk reduction. Early Dutch results already cite safety improvements:
Tesla Full Self-Driving shows stunning maneuver in Europe to silence skeptics
But the work is far from done, and challenges are still present. FSD Supervised still requires driver attention and a readiness to intervene. EU rules emphasize that the technology is not fully autonomous, placing legal responsibility on the human operator. Tesla must also navigate varying national road conditions and public perception.
Nevertheless, the Ireland talks underscore a clear trajectory: one national approval at a time, Europe is inching closer to widespread FSD access. If the Dutch model gains traction, Summer 2026 could mark the beginning of a transformative chapter for autonomous driving on European roads.
Tesla’s persistent engagement with regulators is starting to pay off, and it suggests the company is still heavily committed to the expansion efforts across Europe, despite the red tape it has had to persist through.
Tesla Optimus is already benefiting investors, top Wall Street firm says
Tesla Giga Texas buzzing as new Cybertruck appears to enter production
