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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- [Credit: US Patent Office]
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.
Cybertruck
Tesla confirms date when new Cybertruck trim will go up in price
Tesla has officially revealed that this price will only be available until February 28, as the company has placed a banner atop the Design Configurator on its website reflecting this.
Tesla has confirmed the date when its newest Cybertruck trim level will increase in price, after CEO Elon Musk noted that the All-Wheel-Drive configuration of the all-electric pickup would only be priced at its near-bargain level for ten days.
Last week, Tesla launched the All-Wheel-Drive configuration of the Cybertruck. Priced at $59,990, the Cybertruck featured many excellent features and has seemingly brought some demand to the pickup, which has been underwhelming in terms of sales figures over the past couple of years.
Tesla launches new Cybertruck trim with more features than ever for a low price
When Tesla launched it, many fans and current owners mulled the possibility of ordering it. However, Musk came out and said just hours after launching the pickup that Tesla would only keep it at the $59,990 price level for ten days.
What it would be priced at subsequently was totally dependent on how much demand Tesla felt for the new trim level, which is labeled as a “Dual Motor All-Wheel-Drive” configuration.
Tesla has officially revealed that this price will only be available until February 28, as the company has placed a banner atop the Design Configurator on its website reflecting this:
NEWS: Tesla has officially announced that the price of the new Cybertruck Dual-Motor AWD will be increasing after February 28th. pic.twitter.com/vZpA521ZwC
— Sawyer Merritt (@SawyerMerritt) February 24, 2026
Many fans and owners have criticized Tesla’s decision to unveil a trim this way, and then price it at something, only to change that price a few days later based on how well it sells.
Awful way to treat customers – particularly when they already sent out a marketing email announcing the $59,990 truck…with zero mention of it being a limited-time offer.
— Ryan McCaffrey (@DMC_Ryan) February 24, 2026
It seems the most ideal increase in price would be somewhere between $5,000 and $10,000, but it truly depends on how many orders Tesla sees for this new trim level. The next step up in configuration is the Premium All-Wheel-Drive, which is priced at $79,990.
The difference between the Dual Motor AWD Cybertruck and the Premium AWD configuration comes down to towing, interior quality, and general features. The base package is only capable of towing up to 7,500 pounds, while the Premium can handle 11,000 pounds. Additionally, the seats in the Premium build are Vegan Leather, while the base trim gets the textile seats.
It also has only 7 speakers compared to the 15 that the Premium trim has. Additionally, the base model does not have an adjustable ride height, although it does have a coil spring with an adaptive damping suspension package.
Cybertruck
Tesla set to activate long-awaited Cybertruck feature
Tesla will officially activate the Active Noise Cancellation (ANC) feature on Cybertruck soon, as the company has officially added the feature to its list of features by trim on its website.
Tesla is set to activate a long-awaited Cybertruck feature, and no matter when you bought your all-electric pickup, it has the hardware capable of achieving what it is designed to do.
Tesla simply has to flip the switch, and it plans to do so in the near future.
Tesla will officially activate the Active Noise Cancellation (ANC) feature on Cybertruck soon, according to Not a Tesla App, as the company has officially added the feature to its list of features by trim on its website.
Tesla rolls out Active Road Noise Reduction for new Model S and Model X
The ANC feature suddenly appeared on the spec sheet for the Premium All-Wheel-Drive and Cyberbeast trims, which are the two configurations that have been delivered since November 2023.
However, those trims have both had the ANC disabled, and although they are found in the Model S and Model X, and are active in those vehicles, Tesla is planning to activate them.
In Tesla’s Service Toolbox, it wrote:
“ANC software is not enabled on Cybertruck even though the hardware is installed.”
Tesla has utilized an ANC system in the Model S and Model X since 2021. The system uses microphones embedded in the front seat headrests to detect low-frequency road noise entering the cabin. It then generates anti-noise through phase-inverted sound waves to cancel out or reduce that noise, creating quieter zones, particularly around the vehicle’s front occupants.
The Model S and Model X utilize six microphones to achieve this noise cancellation, while the Cybertruck has just four.
Tesla Cybertruck Dual Motor AWD estimated delivery slips to early fall 2026
As previously mentioned, this will be activated through a software update, as the hardware is already available within Cybertruck and can simply be activated at Tesla’s leisure.
The delays in activating the system are likely due to Tesla Cybertruck’s unique design, which is unlike anything before. In the Model S and Model X, Tesla did not have to do too much, but the Cybertruck has heavier all-terrain tires and potentially issues from the aluminum castings that make up the vehicle’s chassis, which are probably presenting some challenges.
Unfortunately, this feature will not be available on the new Dual Motor All-Wheel-Drive configuration, which was released last week.
News
Tesla Model S and X customization options begin to thin as their closure nears
Tesla’s Online Design Studio for both vehicles now shows the first color option to be listed as “Sold Out,” as Lunar Silver is officially no longer available for the Model S or Model X. This color is exclusive to these cars and not available on the Model S or Model X.
Tesla Model S and Model X customization options are beginning to thin for the first time as the closure of the two “sentimental” vehicles nears.
We are officially seeing the first options disappear as Tesla begins to work toward ending production of the two cars and the options that are available to those vehicles specifically.
Tesla’s Online Design Studio for both vehicles now shows the first color option to be listed as “Sold Out,” as Lunar Silver is officially no longer available for the Model S or Model X. This color is exclusive to these cars and not available on the Model S or Model X.
🚨 Tesla Model S and Model X availability is thinning, as Tesla has officially shown that the Lunar Silver color option on both vehicles is officially sold out
To be fair, Frost Blue is still available so no need to freak out pic.twitter.com/YnwsDbsFOv
— TESLARATI (@Teslarati) February 25, 2026
Tesla is making way for the Optimus humanoid robot project at the Fremont Factory, where the Model S and Model X are produced. The two cars are low-volume models and do not contribute more than a few percent to Tesla’s yearly delivery figures.
With CEO Elon Musk confirming that the Model S and Model X would officially be phased out at the end of the quarter, some of the options are being thinned out.
This is an expected move considering Tesla’s plans for the two vehicles, as it will make for an easier process of transitioning that portion of the Fremont plant to cater to Optimus manufacturing. Additionally, this is likely one of the least popular colors, and Tesla is choosing to only keep around what it is seeing routine demand for.
During the Q4 Earnings Call in January, Musk confirmed the end of the Model S and Model X:
“It is time to bring the Model S and Model X programs to an end with an honorable discharge. It is time to bring the S/X programs to an end. It’s part of our overall shift to an autonomous future.”
Fremont will now build one million Optimus units per year as production is ramped.
Tesla confirms date when new Cybertruck trim will go up in price
Tesla set to activate long-awaited Cybertruck feature
