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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.
SpaceX officially launched the Starlink Mini 2 on November 10, delivering the first portable Starlink terminal designed around independent power.
Invitation-only preorders for select U.S. customers are priced at $999 plus tax, a figure that includes a full year of Roam Unlimited service valued at roughly $2,100. A refundable $100 deposit reserves the kit, with the balance due at shipment, expected to begin in mid-December. Broader availability is listed as coming soon.
Starlink just unveiled Mini 2, its next-gen portable dish.
Quick-swap battery, up to 4.5 hrs per charge
USB-C power
Built-in Wi-Fi
Online in about 60 secondsPreorders are open now. https://t.co/QawqgbswrQ
— TESLARATI (@Teslarati) November 10, 2026
The headline feature is the quick-swap 71 Wh battery. Clipped to the rear of the dish without tools, it delivers up to 4.5 hours of connectivity on a single charge.
The 490-gram pack includes its own USB-C port and LED indicators, so users can charge a spare separately and swap it in seconds while staying online. Starlink notes that the terminal can continue operating while the battery charges or run directly from a 60 W USB-C source. The retail box includes one battery, a 60 W USB-C charger, and a 3-meter cable.
Beyond power, the Mini 2 is thinner at 23.1 mm (versus 38.5 mm on the original Mini) while measuring 263 × 314 mm. With the battery and kickstand attached it weighs 1.6 kg.
Built-in Wi-Fi 6 expands coverage to up to 1,800 square feet, an IP67 rating protects against dust and water, and a standard 1/4-20 tripod thread plus physical power button round out the design. Field of view remains 110 degrees, and the unit retains support for mobile use.
For travelers, campers, and remote workers, the swappable battery removes the longstanding requirement for an external power bank or vehicle outlet that defined the first Mini. Spare packs sold separately further extend runtime, turning the compact terminal into a more self-contained solution.
While the bundled $999 invitation price sits well above the original Mini’s current $149 starting point, the included year of service and genuine untethered operation mark a clear step forward in portable satellite internet.
Elon Musk
SpaceX’s $24B Starbase supercomputer plan slipped past a key roadblock
SpaceX wants a Starbase tax break for a $24 billion gas plant and supercomputer campus.
SpaceX is asking its own company town for a tax break on a $24 billion natural gas power plant and supercomputing facility at Starbase, Texas, and the land it picked sits just outside the reach of a data center moratorium that took effect in neighboring Brownsville last week.
A City of Starbase public hearing notice says SpaceX “proposes to construct, own, and operate a gas-fired power plant and super-compute facility” on roughly 444 acres between Boca Chica Boulevard and the Port of Brownsville. The $24 billion figure covers only the initial phases, and the notice leaves room for future expansions. The Starbase City Commission will consider a property tax abatement and a related economic development agreement at a 7 p.m. hearing on December 9. The notice does not disclose the size or length of the abatement, or how much computing capacity the site would hold.
The location has a history. Over the summer, SpaceX asked Brownsville to remove the tract from its city limits and offered $220 million for water and wastewater projects in return. Brownsville approved the move in August, and Starbase later annexed the land. Brownsville’s own 90-day pause on data center applications took effect last week, and had the tract stayed inside the city, the project likely would have needed a different home.
The power side is already in front of state regulators. SpaceX has applied to the Texas Commission on Environmental Quality for air permits covering 35 mobile gas turbines producing roughly 750 megawatts, according to Politico, which also noted that two of the three Starbase commissioners voting on the incentives are SpaceX executives.
Building its own plant lets SpaceX skip the Texas grid. Gov. Greg Abbott paused new data center grid connections in August pending an audit, but a facility that generates its own electricity does not need one. The air permit still has to clear the TCEQ, where Abbott also ordered a halt on data center permits.
The bigger test arrives in January. Governor-elect Gina Hinojosa, who unseated Abbott last week, has said she will block data center approvals until the legislature passes new protections, and she has already asked state officials to hold off on any sale of Boca Chica State Park to SpaceX until she is sworn in. Tesla and SpaceX shares both fell the day after the election, and Musk’s first reaction on X was “Data centers in space looking pretty appealing right now.”
That line points to Starmind, SpaceX’s orbital compute constellation. Musk has said terrestrial compute will be “peanuts compared to orbital compute” and expects monthly orbital deployments to pass ground deployments around the end of 2028, as Teslarati reported. Until then, SpaceX still needs gigawatts on the ground. It ended the third quarter with 1.7 GW of nameplate compute, is targeting 2.5 to 3 GW by the end of this year and wants at least 10 GW more in 2027. Its existing Colossus sites around Memphis already run on gas turbines and face a lawsuit from residents over emissions.
Local reaction is split. The South Texas Environmental Justice Network has announced a protest, citing air quality, water use and energy bills, while some Brownsville residents told the Tribune they welcome the jobs. SpaceX did not respond to the Tribune’s questions about the project.
Tesla CEO Elon Musk announced that the company will extend Cybertruck production slightly to handle its extensive order backlog.
On Wednesday, Musk announced that “In order to work through more of the Cybertruck order backlog, production will be extended through the end of summer 2027.”
In order to work through more of the Cybertruck order backlog, production will be extended through the end of summer 2027
— Elon Musk (@elonmusk) November 11, 2026
Tesla has already attempted to simplify its last months of production for the Cybertruck by eliminating several trim levels and only offering the Cyberbeast, the most expensive trim that starts at $109,990. The other two trim levels, the Cybertruck All-Wheel-Drive and Premium All-Wheel-Drive have both been discontinued.
There has been plenty of backlash against Tesla’s decision to ax the Cybertruck, but the company’s forecast prioritizes Cybercab and autonomy. Factory space at Gigafactory Texas that is not necessary is now being set aside for the Cybercab as the company truly embraces its “transportation-as-a-service” model.
There is still a slim chance the Cybertruck survives. Last evening, Tesla upfitter Unplugged Performance offered to take the Cybertruck line off of Tesla’s hands and continue building it, along with a CyberSUV.
Nevertheless, Tesla seems to be ending the Cybertruck on its terms after what will be a three-and-a-half-year run. It still does not really feel quite real; I think many of us thought the Cybertruck would be around for years to come.
Musk added more detail, stating that while it was not the smartest move, “there must be some room in this world for sentimentality or what’s the point?”
This is not the smartest move from a profit-maximizing standpoint btw, but there must be some room in this world for sentimentality or what’s the point?
— Elon Musk (@elonmusk) November 11, 2026
Other EV pickups on the market have experienced a similar fate.
The Ford F-150 Lightning was axed by the Detroit company due to the continued losses the company took from sales. That truck was never profitable, and Ford is still taking a quarterly loss in its EV side. However, things are moving along as it has plans for a mass market EV pickup, which will likely gather some substantial demand if Ford can get it just right.
Perhaps another extension or even a total change of heart might come. Only Musk knows.
Starlink Mini 2 arrives with one feature for true off-grid connectivity
SpaceX’s $24B Starbase supercomputer plan slipped past a key roadblock
