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Tesla patent addresses panel gaps using clever clamping assembly

[Credit: Chuck Dickey/Twitter]

Published

7 years ago

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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.”

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.

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“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.”

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.

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“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.

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Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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Tesla Robotaxi is headed to New York City, but one thing is in its way

Tesla is working to hire Vehicle Operators in New York City, but the company still needs some regulatory hurdles to go through.

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1 hour ago

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August 12, 2025

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Credit: Tesla

Tesla Robotaxi will be headed to New York City, but there is one huge thing that stands in its way: approval to test autonomous vehicles.

Tesla is expanding its Robotaxi platform across the United States as it currently operates in Austin, Texas, and the Bay Area of California.

The company has also been seeking approvals in several other states, including Nevada, Arizona, and Florida.

However, the company is also working to expand to major metropolitan areas across the U.S. that it has not explicitly mentioned, as it attempts to reach CEO Elon Musk’s goal of giving half of the country’s population access to the platform by the end of the year:

It appears New York City is next on the list, according to a job posting on Tesla’s Careers website.

The company says it is hiring a Vehicle Operator for Autopilot in Flushing, New York, a section of the borough of Queens. Queens is connected to Brooklyn and Long Island, so it seems more ideal than launching in Manhattan or the Bronx, where traffic is heavy and charging is not as readily available.

Tesla’s job posting states:

“We are looking for a highly motivated self-starter to join our vehicle data collection team. As a Prototype Vehicle Operator, you will be responsible for driving an engineering vehicle for extended periods, conducting dynamic audio and camera data collection for testing and training purposes. Access to the data collected is limited to the applicable development team. This role requires a high level of flexibility, strong attention to detail, excellent driving skills, and the ability to thrive in a fast-paced, dynamic environment.”

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It also lists the hours of operation as Tuesday through Saturday or Sunday through Thursday, with its three shifts listed as:

  • Day Shift: 6:00 AM – 2:30 PM or 8:00 AM – 4:30 PM
  • Afternoon Shift: 2:00 PM – 10:30 PM or 4:00 PM – 12:30 AM
  • Night Shift: 10:00 PM-6:30 AM or 12:00 AM-8:30 AM

We wouldn’t count on New York City being the next place Tesla launches Robotaxi. According to a report from CNBC, a spokesperson for the NYC Department of Transportation confirmed Tesla has not yet applied for permits that are needed to operate its ride-hailing service.

For what it’s worth, it could just be the first step in Tesla’s plans. It also has Vehicle Operator job postings in other regions. Houston, Texas, as well as Tampa, Miami, and Clermont, Florida, are all listed on Tesla’s Career postings.

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Tesla’s Elon Musk gives nod to Ford while acknowledging his influence on EVs

“Ford basically invented mass manufacturing of large, complex products. Everyone else copied.”

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2 hours ago

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August 12, 2025

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Credit: Tesla, Ford

Tesla CEO Elon Musk gave a tremendous nod to Ford while also acknowledging his own influence on EVs and the automotive industry in general.

Yesterday, Ford announced its new manufacturing process for EVs, which was essentially a rebirth of its own production lines and plans for more affordable models to offer consumers.

It was important to recognize that Ford truly launched automotive manufacturing with its production of the Model T 122 years ago.

That’s exactly what Musk did in a response to Ford CEO Jim Farley:

In the over 100 years since Ford started producing vehicles, the company has had one significant fact go under the radar: it truly created a great process for building large, complex vehicles. It is something that many companies eventually adopted as the car industry took off.

Tesla is in a similar situation. It has used things like the Giga Press from the Italian company IDRA to create a better, more efficient, streamlined process for building cars.

It was able to use casting to eliminate a vast majority of parts from the Model Y, which not only helped increase manufacturing efficiency but also improved safety and structural rigidity. It truly revolutionized manufacturing for the company, and Ford said that it would adopt a similar mindset with its new EVs.

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Yesterday, Doug Field, the Chief EV, Digital and Design Officer for Ford, and a former Sr. VP of Engineering for Tesla, said the company was taking the mentality that “the best part is no part.”

Musk acknowledged how far it has come and how it is influencing other car companies to do the same in terms of its production strategy:

Ford is using an “Assembly Tree,” which is essentially very similar to Tesla’s “unboxed production process.” In addition to the use of Gigacasting, which Ford is calling “Unicasting,” as well as the use of structural batteries, it is almost as if Tesla is having its own “Model T moment.”

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Ford has been quick to adopt an EV mentality as it plans to transition its business over the next decades. It is working to prepare for the future of the atuomotive industry, and although it has adjusted its strategy, it can’t be denied that Ford is one of the legacy automakers taking this new chapter in cars seriously.

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Tesla has one big bottleneck with its public Robotaxi launch, but it can fix it easily

Elon Musk plans for Tesla Robotaxi to be open to the public in Austin in September.

Published

2 hours ago

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August 12, 2025

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Credit: Dave Lee

Tesla CEO Elon Musk said that the company’s Robotaxi program would open to the public in September, but there is one big bottleneck that would inhibit it from launching smoothly.

The thing is, it can be resolved in no time, and Tesla can fix it internally.

In Austin, the Robotaxi platform has been in operation since late June. The launch of the program only allowed a handful of privileged influencers and groups to access the driverless ride-hailing service, although it has expanded this group on several occasions.

It has also slowly added vehicles to the fleet, starting at 11 cars when it launched in June. There have been a few cars added, but Tesla has continued to prioritize safety, keeping its rider population and number of vehicles low for the time being.

However, this is going to cause quite a bit of a bottleneck in next month’s planned public launch, as there will be an open invitation for anyone and everyone to test out the Robotaxi platform in Austin.

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Tesla CEO Elon Musk confirms Robotaxi is opening to the public: here’s when

Many people have been waiting for an invitation to ride in a Robotaxi, and Tesla has not been prone to give one to just anybody.

As that becomes a much larger number next month, Tesla is going to have to step up its Robotaxi fleet number, as well as its population of Safety Monitors, the riders that sit in the passenger seat to ensure everything goes smoothly.

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While the geofence in Austin has roughly doubled in size twice during both of Tesla’s expansions of the service area, the company is still playing it safe with rider population growth, something that aligns with its focus on safety.

Musk said recently about the expansion of Robotaxi to customer-owned vehicles:

“As I said, we’re being paranoid about safety. But I guess next year is I’d say confidently next year. I’m not sure when next year, but confidently next year, people would be able to add or subtract their car to the Tesla, Inc. fleet.”

The Robotaxi fleet will, without a doubt, revolutionize the way people view ride-hailing. Tesla seems ready to open it up to the public next month, based on what Musk said, but some changes will have to occur to ensure it goes smoothly.

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