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.”
- [Credit: US Patent Office]
- [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.”
- [Credit: US Patent Office]
- [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.
News
Tesla gathers 93,000 FSD miles in a country where FSD isn’t approved – here’s how
Tesla has quietly logged an impressive 93,000 miles (roughly 150,000 km) of autonomous driving at its Giga Berlin factory—using Full Self-Driving (FSD) in a country where the technology remains unavailable to consumers on public roads.
Tesla has gathered 93,000 Full Self-Driving miles in a country where Full Self-Driving is not even approved. Here’s how.
Tesla has quietly logged an impressive 93,000 miles (roughly 150,000 km) of autonomous driving at its Giga Berlin factory—using Full Self-Driving (FSD) in a country where the technology remains unavailable to consumers on public roads.
The milestone, revealed alongside news that Giga Berlin has now built 750,000 Model Y vehicles, highlights how Tesla is putting its AI to work in one of the most controlled environments imaginable: it’s own factory floor.
Every Model Y that rolls off the final assembly line at Giga Berlin doesn’t need a human driver to reach the outbound lot. Instead, the freshly built vehicles engage FSD and navigate themselves across the factory campus.
The Tesla Model Ys rolling off the production line at Giga Berlin have now driven themselves on FSD a combined 93,000 miles from the end of the production line to the outbound lot. https://t.co/6RhL3W4q4p pic.twitter.com/DOKKHUcSSL
— Sawyer Merritt (@SawyerMerritt) May 11, 2026
The route—from the end of the production line through marked internal pathways to the staging area where cars await delivery or export—is entirely on private property. No public roads, no mixed traffic, and no regulatory hurdles for on-road autonomous operation.
It’s a closed-loop system: wide lanes, predictable layouts, minimal pedestrians, and consistent conditions that make it one of the simplest proving grounds for the software.
A short factory tour video shared by Tesla Manufacturing shows General Assembly team member Jan explaining the process. Gesturing beside a glossy black Model Y still wearing its protective wrap, he notes the cumulative distance the fleet has covered autonomously.
Tesla Giga Berlin seems to be using FSD Unsupervised to move Model Y units
The cars handle the short drive flawlessly, freeing up workers who would otherwise spend hours shuttling vehicles manually. For a high-volume plant like Giga Berlin, the time and labor savings add up quickly. Even small gains in cycle time per car can reclaim valuable space in the outbound lot and streamline logistics.
This internal deployment serves multiple purposes. First, it delivers zero-cost validation data. Each factory run exposes FSD to real-world physics—acceleration, steering precision, obstacle avoidance—in a repeatable setting far safer than public testing.
Second, it demonstrates the system’s readiness at scale. If FSD can reliably move thousands of brand-new cars without intervention inside a busy factory, it underscores the robustness of the vision-based, end-to-end neural network Tesla has been refining.
Critics often point to Europe’s cautious regulatory stance on unsupervised autonomy, yet Tesla has turned that limitation into an advantage. While owners in Germany still cannot activate consumer FSD on highways or city streets, the software is already proving its worth behind the factory gates.
The 93,000 miles represent not just internal efficiency gains but a subtle flex: the cars are manufactured ready to navigate autonomously, at least in the bounds of the factory. It’s a big feather in the cap of FSD, even if regulators have yet to green-light broader use.
As Giga Berlin continues ramping output, expect this autonomous logistics loop to grow. What began as a practical workaround for moving finished vehicles has quietly become one of the most compelling real-world showcases of FSD’s potential—right in the heart of regulated Europe. Tesla isn’t waiting for approval to perfect its autonomy; it’s already driving the future, one factory mile at a time.
Elon Musk
Elon Musk reveals how SpaceX is always on board Air Force One
Musk confirmed Tuesday that Starlink internet is live and kicking on Air Force One. Responding with a simple “Yup!” to a post showing him and Nvidia CEO Jensen Huang aboard the presidential jet en route to Beijing with President Trump, Musk proved the point: America’s most important aircraft now has seamless, high-speed satellite connectivity—even over the middle of the Pacific.
Air Force One, the official call sign for a U.S. Air Force aircraft carrying the President, now runs on SpaceX Starlink, CEO Elon Musk revealed.
Musk confirmed Tuesday that Starlink internet is live and kicking on Air Force One. Responding with a simple “Yup!” to a post showing him and Nvidia CEO Jensen Huang aboard the presidential jet en route to Beijing with President Trump, Musk proved the point: America’s most important aircraft now has seamless, high-speed satellite connectivity—even over the middle of the Pacific.
Yup!
— Elon Musk (@elonmusk) May 13, 2026
The timing couldn’t be more symbolic. With trillion-dollar CEOs and the President sharing the cabin, Starlink wasn’t just a nice-to-have—it was mission-critical. No more spotty signals or dropped calls. Instead, real-time video conferences, secure data transfers, and global coordination at Mach speed.
Starlink’s aviation push has already transformed commercial and private flying. Dozens of major airlines have signed on or begun rollouts.
Hawaiian Airlines, United Airlines, Qatar Airways, Air France, SAS, WestJet, airBaltic, and Emirates (now equipping its Boeing 777 and A380 fleets) offer Starlink Wi-Fi to passengers. Lufthansa plans to follow in late 2026.
On private jets, the upgrade is even hotter: owners and charter companies report skyrocketing demand because Starlink turns cabins into flying boardrooms.
Starlink gets its latest airline adoptee for stable and reliable internet access
The advantages are massive. Traditional in-flight Wi-Fi relied on slow, high-latency geostationary satellites or ground-based systems that cut out over oceans and remote areas. Starlink’s low-Earth-orbit constellation delivers blazing speeds—often exceeding 200 Mbps download with latency as low as 25-60 milliseconds—gate-to-gate, from takeoff to landing.
Passengers stream 4K video, join Zoom calls, or work in the cloud without buffering. Pilots get real-time weather, NOTAM updates, and live ATC data. Even private-jet travelers get the benefits, as it means productivity that rivals the office.
On Air Force One, those benefits become strategic superpowers. The presidential aircraft demands unbreakable communications for national security, diplomacy, and crisis response. Starlink provides global coverage with no dead zones, offering redundancy against traditional systems that could fail in contested airspace or during long-haul flights.
It enables the President and staff to maintain secure links with the Pentagon, allies, or business leaders anywhere on Earth. During the Beijing trip, it likely facilitated direct coordination on trade, tech, and AI—proving the system’s reliability for the highest-stakes missions.
Critics once dismissed Starlink as a rich-person toy or military experiment. Now, it’s the backbone of commercial fleets, private aviation, and the world’s most visible symbol of American power, and it is providing stable internet to travelers.
With over 2,000 commercial aircraft committed and private-jet installations booming, Starlink is rewriting the rules of connected flight, and it seems like each week, a new airline is choosing to use it for on-flight connectivity.
For Air Force One, it’s more than faster Wi-Fi. It’s uninterrupted command-and-control in an increasingly connected world—ensuring the President never has to go dark at altitude. Elon Musk just made sure of it.
Elon Musk
SpaceX unveils sweeping Starship V3 upgrades ahead of May 19 launch
SpaceX has released a detailed list of changes for Starship Version 3, the next iteration of its fully reusable super-heavy-lift vehicle. Scheduled for its maiden flight as early as May 19 from Starbase in Texas, Starship V3 incorporates dozens of redesigns across the Super Heavy booster, Starship upper stage, Raptor 3 engines, and Launch Pad 2.
SpaceX has unveiled sweeping upgrades to its Starship v3 rocket ahead of the upcoming May 19 launch.
SpaceX has released a detailed list of changes for Starship Version 3, the next iteration of its fully reusable super-heavy-lift vehicle. Scheduled for its maiden flight as early as May 19 from Starbase in Texas, Starship V3 incorporates dozens of redesigns across the Super Heavy booster, Starship upper stage, Raptor 3 engines, and Launch Pad 2.
Elon Musk reveals date of SpaceX Starship v3’s maiden voyage
The updates focus on simplification, mass reduction, reliability, and enabling core capabilities like rapid reusability, in-orbit refueling, Starlink deployment, and crewed missions to the Moon and Mars.
Collectively, these modifications mark a major step-change. By reducing dry mass, improving thermal protection, and integrating systems for orbital operations, Starship V3 aims to transition from test vehicle to operational infrastructure.
Here is an explicit, broken-down list of the key changes, first starting with the changes to Super Heavy V3:
- Grid Fin Redesign: Reduced from four fins to three. Each fin is now 50% larger and stronger, repositioned for better catching and lifting performance. Fins are lowered on the booster to reduce heat exposure during hot staging, with hardware moved inside the fuel tank for protection.
- Integrated Hot Staging: Eliminates the old disposable interstage shield. The booster dome is now directly exposed to upper-stage engine ignition, protected by tank pressure and steel shielding. Interstage actuators retract after separation.
- New Fuel Transfer System: Massive redesign of the fuel transfer tube—roughly the size of a Falcon 9 first stage—enables simultaneous startup of all 33 Raptors for faster, more reliable flip maneuvers.
- Engine Bay / Thermal Protection: Engine shrouds removed entirely; new shielding added between engines. Propulsion and avionics are more tightly integrated. CO₂ fire suppression system deleted for a simpler, lighter aft section.
- Propellant Loading Improvements: Switched from one quick disconnect to two separate systems for added redundancy and reduced pad complexity.
Next, we have the changes to Starship V3:
- Completely Redesigned Propulsion System: Clean-sheet redesign supports new Raptor startup, larger propellant volume, and an improved reaction control system while reducing trapped or leaked propellant risk.
- Aft Section Simplification: Fluid and electrical systems rerouted; engine shrouds and large aft cavity deleted.
- Flap Actuation Upgrade: Changed from two actuators per flap to one actuator with three motors for better redundancy, mass efficiency, and lower cost.
- Faster Starlink Deployment: Upgraded PEZ dispenser enables quicker satellite release.
- Long-Duration Spaceflight Capability: New systems for long orbital coasts, orbital refueling, cryogenic fluid management, vacuum-insulated header tanks, and high-voltage cryogenic recirculation.
- Ship-to-Ship Docking + Refueling: Four docking drogues and dedicated propellant transfer connections added to support in-space refueling architecture.
- Avionics Upgrades: 60 custom avionics units with integrated batteries, inverters, and high-voltage systems (9 MW peak power). New multi-sensor navigation for precision autonomous flight. RF sensors measure propellant in microgravity. ~50 onboard camera views and 480 Mbps Starlink connectivity for low-latency communications.
Next are the changes to the Raptor 3 Engine:
- Higher Thrust: Sea-level Raptors increased from 230 tf (507k lbf) to 250 tf (551k lbf); vacuum Raptors from 258 tf (568k lbf) to 275 tf (606k lbf).
- Lower Mass: Sea-level engine mass reduced from 1630 kg to 1525 kg.
- Simpler Design: Sensors and controllers integrated into the engine body; shrouds eliminated; new ignition system for all variants. Results in ~1 ton of vehicle-level weight savings per engine.
Finally, the upgrades to Launch Pad 2 are as follows:
- Faster propellant loading via larger farm and more pumps.
- Chopstick improvements: shorter arms, electromechanical actuators (replacing hydraulic) for reliability.
- Stronger quick-disconnect arm that swings farther away.
- Redesigned launch mount for better load handling and protection.
- New bidirectional flame diverter eliminates post-launch ablation and refurbishment.
- Hardened propellant systems with separated methane/oxygen lines and protected valves/filters.
SpaceX states these elements “are designed to enable a step-change in Starship capabilities and aim to unlock the vehicle’s core functions, including full and rapid reuse, in-space propellant transfer, deployment of Starlink satellites and orbital data centers, and the ability to send people and cargo to the Moon and Mars.”
With these upgrades, Starship V3 is poised for an epic test flight that could accelerate humanity’s multiplanetary future. The rapid pace of iteration underscores SpaceX’s relentless drive toward making life multiplanetary. Launch watchers are in for a spectacular show.



