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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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- [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.
Tesla recently released Full Self-Driving (FSD) v14.2.1, its latest version, but the tinkering with Speed Profiles has perhaps gone too far.
We try to keep it as real as possible with Full Self-Driving operation, and we are well aware that with the new versions, some things get better, but others get worse. It is all part of the process with FSD, and refinements are usually available within a week or so.
However, the latest v14.2.1 update has brought out some major complaints with Speed Profiles, at least on my end. It seems the adjustments have gone a tad too far, and there is a sizeable gap between Profiles that are next to one another.
Tesla FSD v14.2.1 first impressions:
✅ Smooth, stress-free highway operation
✅ Speed Profiles are refined — Hurry seems to be limited to 10 MPH over on highways. Switching from Mad Max to Hurry results in an abrupt braking pattern. Nothing of concern but do feel as if Speed…— TESLARATI (@Teslarati) November 29, 2025
The gap is so large that changing between them presents a bit of an unwelcome and drastic reduction in speed, which is perhaps a tad too fast for my liking. Additionally, Speed Profiles seem to have a set Speed Limit offset, which makes it less functional in live traffic situations.
Before I go any further, I’d like to remind everyone reading this that what I am about to write is purely my opinion; it is not right or wrong, or how everyone might feel. I am well aware that driving behaviors are widely subjective; what is acceptable to one might be unacceptable to another.
Speed Profiles are ‘Set’ to a Speed
From what I’ve experienced on v14.2.1, Tesla has chosen to go with somewhat of a preset max speed for each Speed Profile. With ‘Hurry,’ it appears to be 10 MPH over the speed limit, and it will not go even a single MPH faster than that. In a 55 MPH zone, it will only travel 65 MPH. Meanwhile, ‘Standard’ seems to be fixed at between 4-5 MPH over.
This is sort of a tough thing to have fixed, in my opinion. The speed at which the car travels should not be fixed; it should be more dependent on how traffic around it is traveling.
-->It almost seems as if the Speed Profile chosen should be more of a Behavior Profile. Standard should perform passes only to traffic that is slower than the traffic. If traffic is traveling at 75 MPH in a 65 MPH zone, the car should travel at 75 MPH. It should pass traffic that travels slower than this.
Hurry should be more willing to overtake cars, travel more than 10 MPH over the limit, and act as if someone is in a hurry to get somewhere, hence the name. Setting strict limits on how fast it will travel seems to be a real damper on its capabilities. It did much better in previous versions.
Some Speed Profiles are Too Distant from Others
This is specifically about Hurry and Mad Max, which are neighbors in the Speed Profiles menu. Hurry will only go 10 MPH over the limit, but Mad Max will travel similarly to traffic around it. I’ve seen some people say Mad Max is too slow, but I have not had that opinion when using it.
In a 55 MPH zone during Black Friday and Small Business Saturday, it is not unusual for traffic around me to travel in the low to mid-80s. Mad Max was very suitable for some traffic situations yesterday, especially as cars were traveling very fast. However, sometimes it required me to “gear down” into Hurry, especially as, at times, it would try to pass slower traffic in the right lane, a move I’m not super fond of.
We had some readers also mention this to us:
-->The abrupt speed reduction when switching to a slower speed profile is definitely an issue that should be improved upon.
— David Klem (@daklem) November 29, 2025
After switching from Mad Max to Hurry, there is a very abrupt drop in speed. It is not violent by any means, but it does shift your body forward, and it seems as if it is a tad drastic and could be refined further.
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Tesla’s most affordable car is coming to the Netherlands
The trim is expected to launch at €36,990, making it the most affordable Model 3 the Dutch market has seen in years.
Tesla is preparing to introduce the Model 3 Standard to the Netherlands this December, as per information obtained by AutoWeek. The trim is expected to launch at €36,990, making it the most affordable Model 3 the Dutch market has seen in years.
While Tesla has not formally confirmed the vehicle’s arrival, pricing reportedly comes from a reliable source, the publication noted.
Model 3 Standard lands in NL
The U.S. version of the Model 3 Standard provides a clear preview of what Dutch buyers can expect, such as a no-frills configuration that maintains the recognizable Model 3 look without stripping the car down to a bare interior. The panoramic glass roof is still there, the exterior design is unchanged, and Tesla’s central touchscreen-driven cabin layout stays intact.
Cost reductions come from targeted equipment cuts. The American variant uses fewer speakers, lacks ventilated front seats and heated rear seats, and swaps premium materials for cloth and textile-heavy surfaces. Performance is modest compared with the Premium models, with a 0–100 km/h sprint of about six seconds and an estimated WLTP range near 550 kilometers.
Despite the smaller battery and simpler suspension, the Standard maintains the long-distance capability drivers have come to expect in a Tesla.
-->Pricing strategy aligns with Dutch EV demand and taxation shifts
At €36,990, the Model 3 Standard fits neatly into Tesla’s ongoing lineup reshuffle. The current Model 3 RWD has crept toward €42,000, creating space for a more competitive entry-level option, and positioning the new Model 3 Standard comfortably below the €39,990 Model Y Standard.
The timing aligns with rising Dutch demand for affordable EVs as subsidies like SEPP fade and tax advantages for electric cars continue to wind down, EVUpdate noted. Buyers seeking a no-frills EV with solid range are then likely to see the new trim as a compelling alternative.
With the U.S. variant long established and the Model Y Standard already available in the Netherlands, the appearance of an entry-level Model 3 in the Dutch configurator seems like a logical next step.
News
Tesla Model Y is still China’s best-selling premium EV through October
The premium-priced SUV outpaced rivals despite a competitive field, while the Model 3 also secured an impressive position.
The Tesla Model Y led China’s top-selling pure electric vehicles in the 200,000–300,000 RMB segment through October 2025, as per Yiche data compiled from China Passenger Car Association (CPCA) figures.
The premium-priced SUV outpaced rivals despite a competitive field, while the Model 3 also secured an impressive position.
The Model Y is still unrivaled
The Model Y’s dominance shines in Yiche’s October report, topping the chart for vehicles priced between 200,000 and 300,000 RMB. With 312,331 units retailed from January through October, the all-electric crossover was China’s best-selling EV in the 200,000–300,000 RMB segment.
The Xiaomi SU7 is a strong challenger at No. 2 with 234,521 units, followed by the Tesla Model 3, which achieved 146,379 retail sales through October. The Model Y’s potentially biggest rival, the Xiaomi YU7, is currently at No. 4 with 80,855 retail units sold.
Efficiency kings
The Model 3 and Model Y recently claimed the top two spots in Autohome’s latest real-world energy-consumption test, outperforming a broad field of Chinese-market EVs under identical 120 km/h cruising conditions with 375 kg payload and fixed 24 °C cabin temperature. The Model 3 achieved 20.8 kWh/100 km while the Model Y recorded 21.8 kWh/100 km, reaffirming Tesla’s efficiency lead.
The results drew immediate attention from Xiaomi CEO Lei Jun, who publicly recognized Tesla’s advantage while pledging continued refinement for his brand’s lineup.
-->“The Xiaomi SU7’s energy consumption performance is also very good; you can take a closer look. The fact that its test results are weaker than Tesla’s is partly due to objective reasons: the Xiaomi SU7 is a C-segment car, larger and with higher specifications, making it heavier and naturally increasing energy consumption. Of course, we will continue to learn from Tesla and further optimize its energy consumption performance!” Lei Jun wrote in a post on Weibo.
Tesla tinkering with Speed Profiles on FSD v14.2.1 has gone too far
Tesla’s most affordable car is coming to the Netherlands
