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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.”
- [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 Full Self-Driving impressions after three weeks of ownership
I will be fair and tell you all what I truly enjoy, as well as what frustrates me about Full Self-Driving.

Tesla Full Self-Driving is amongst the most robust and refined semi-autonomous driver assistance systems on the market today. After three weeks of ownership, I’ve driven around half of my miles using it, and my impressions put me right in the middle of it being very impressive and needing some work.
Of course, if it were perfect, it would be driving us all around all the time while we sleep, scroll our phones, or watch movies in the cockpit. It does a lot of things very well, and it has managed to impress everyone I’ve put in the passenger’s seat.
However, there are some things that are obvious pain points, situations that need improvement, and areas where I believe it has a long way to go. Regardless, these are things I have noticed, and they may differ from your opinions based on your location or traffic situations.
Tesla Model Y ownership two weeks in: what I love and what I don’t
I’ll try to keep it pretty even and just highlight the things that are truly noticeable with Full Self-Driving. I won’t be too critical of the things that it is bad at, and I won’t try to give it too much of a pat on the back.
I will be fair and tell you all what I truly enjoy, as well as what frustrates me about it.
*Disclaimer: These Full Self-Driving examples were in use with v13.2.9.
Where Tesla Full Self-Driving is Great
Highway Driving
I have yet to have a critical intervention of any kind on the highway. I have driven on easy highways like Rt. 30 in Pennsylvania, and I have driven on congested four-lane parking lots like I-695 near Baltimore, Maryland.
Tesla FSD does a tremendous job on all of it. I usually use the “Hurry” setting of FSD with an offset of between 25 and 40 percent, depending on what I’m doing and where I’m going. Sometimes, I want to push it a bit, and at other times, I’m okay with taking my time and enjoying the drive.
I find the driving style of Hurry is more similar to the traffic around me than the Standard, which tends to drive like an 80-year-old on their way to Bingo.
It does a great job of being considerate, maintaining an appropriate rate of travel, getting over for cars that are tailgating in the left lane after passing traffic, and it always is where it needs to be when it needs to be there.
Taking the Stress Out of Driving
A few nights ago, I was having some trouble sleeping, and I was up at 3 a.m. I decided it would be a good time to get up, grab a breakfast burrito and a coffee, and head to the Supercharger.
(If you don’t know, I do not have home charging, and I will be diving into EV ownership without that in a future article.)
I let FSD drive me to the Supercharger and back while I was done. I was able to enjoy a beautiful sunrise without having to focus all my attention on the traffic around me, while still maintaining enough attention to the road to keep the driver monitoring happy.
It was really nice. I enjoyed the ride, and it felt like I was in an Uber with a very careful driver while I enjoyed the rest of my coffee and peeked at the sky every few seconds.
Learning and Improving
A few weeks ago, I approached an “Except Right Turn” stop sign. I have discussed how these are a Pennsylvania specialty, and the first time FSD encountered one in my Model Y, it stopped, even though we were heading right.
I took over, submitted a voice memo to Tesla about it, and went on with my evening. A week later, the car approached the same turn, and, to my surprise, it proceeded through the Stop Sign correctly, safely, and at an appropriate speed.
It was nice to see this improvement, especially since this is one of those regional issues that Tesla will need to address before FSD is fully autonomous. The change even impressed my Fiancé, who was with me during both instances we came upon this turn.
Where Tesla Full Self-Driving Could Be Better
Auto Wipers
Good gravy, these Auto Wipers always seem to give me a good laugh.
They never really have the right speed; they are either way too fast or not fast enough. There’s never been a happy medium.
It also loves to activate a single wipe of the blade at the strangest times. I’ve noticed that it actually seems to activate at the same spots on the road sometimes. There’s a hanging branch near my house, and every time we go under it and FSD is activated, the wipers wipe once.
It would be nice to set your own intervals for the wipers, but I am okay with the current presets. I do hope the Auto Wipers improve, because it could be one of the best features the car has if it’s more accurate.
It Struggles with Signs That Require Reading
The “Except Right Turn” sign is one example, but another is a “Stop Here on Red” sign that is recessed from an intersection at a stop light if it’s a tighter turn. Recently, I had to slam on the brakes as it was headed straight through one of these signs.
It can recognize Stop Signs and Yield Signs, but signs with instructions for an intersection appear to present a greater challenge for FSD.
Sometimes, It Just Does Things I Don’t Like
There is a four-lane light near my house; the two right lanes go straight, but the lane furthest right is for turning into businesses past the intersection. Some people tend to go in that far right lane, even if they have no intention of turning right into the businesses, and take off quickly from the light to cut ahead.
I’m not saying it’s illegal or even wrong, but I personally prefer not to do it. I am never in that much of a hurry.
FSD tried to do that the other day; I intervened and kept it in the lane that is designed to go straight. I wouldn’t say this is technically an intervention. I would just say it’s a move I wasn’t super comfortable with because I know people tend to get frustrated with those who cut the line. It’s an etiquette issue, and I didn’t want FSD to do it.
I also am not a huge fan of when there is no traffic in the right lane, yet it continues to cruise in the fast lane. I was taught to drive in the right lane and pass in the left lane. There are states where cruising in the left lane is illegal, and it sometimes tends to stay in the passing lane too long for my liking. I will turn on my right signal and get back into the correct lane.
These are totally disputable, and I am aware of that. Some people might not see a huge issue with these two examples, and I can understand that. My courtesy on the road differs from others, and that’s okay.
All in all, I’m pretty happy with FSD, and I will be continuing my Subscription after the three-month trial ends. In the coming days, I’ll be picking up a camera for FSD videos, and I’ll be able to embed examples of what I mean, as well as share full-length videos of my drive.
News
Tesla gets price target increase on Wall Street, but it’s a head-scratcher
Delaney’s price target on Tesla shares went up to $395 from $300. Currently, Tesla is trading between $420 and $430, making the new price target from Goldman Sachs a bit of a head-scratcher.

Tesla (NASDAQ: TSLA) received a price target increase from a Wall Street analyst today, who noted in his report that the company’s shares could rise or fall based on its execution in robotics and autonomy.
However, the price target boost still fell below Tesla’s current trading levels.
Mark Delaney of Goldman Sachs said in a note to investors today that Tesla has a significant opportunity to solidify itself as one of the stable and safe plays in the market if it can execute on its two key projects: humanoid robots and autonomy.
In the note, Delaney said:
“If Tesla can have [an] outsized share in areas such as humanoid robotics and autonomy, then there could be upside to our price target.”
Delaney’s price target on Tesla shares went up to $395 from $300. Currently, Tesla is trading between $420 and $430, making the new price target from Goldman Sachs a bit of a head-scratcher.
He went on to say that Tesla could also confront outside factors that would limit the stock’s ability to see growth, including competition and potentially its own lack of execution:
“…although if competition limits profits (as is happening with the ADAS market in China) or Tesla does not execute well, then there could be downside.”
The note is an interesting one because it seems to point out the blatantly obvious: if Tesla performs well, the stock will rise. If it doesn’t, the stock price will decline.
We discussed yesterday in an article that Tesla is one of the few stocks out there that does not seem to be influenced by financials or anything super concrete. Instead, it is more influenced by the narrative currently surrounding the company, rather than the technicals.
Tesla called ‘biggest meme stock we’ve ever seen’ by Yale associate dean
Tesla’s prowess in robotics and autonomy is strong. In robotics, it has a very good sentiment following its Optimus project, and it has shown steady improvement with subsequent versions of the robot with each release.
On the autonomy front, Tesla is expanding its Robotaxi platform in Austin every few weeks, and also has a sizeable geofence in the Bay Area. Its Full Self-Driving suite is among the most robust in the world and is incredibly useful and accurate.
The company can gain significant value if it continues to refine the platform and eventually rolls out a driverless or unsupervised version of the Full Self-Driving suite.
Elon Musk
Tesla addresses door handle complaints with simple engineering fix
“We’ll have a really good solution for that. I’m not worried about it.”

Tesla is going to adjust one heavily scrutinized part of its vehicles after recent government agencies have launched probes into an issue stemming from complaints from owners.
Over the past few days, we have reported on the issues with Tesla’s door handle systems from both the Chinese and American governments.
In China, it dealt with the Model S, while the United States’ National Highway Traffic Safety Administration (NHTSA) reported nine complaints from owners experiencing issues with 2021 Model Ys, as some said they had trouble entering their car after the 12V battery was low on power.
Bloomberg, in an interview with Tesla Chief Designer Franz von Holzhausen, asked whether the company planned to adjust the door handle design to alleviate any concerns that regulatory agencies might have.
Regarding the interior latch concerns in the United States:
- Von Holzhausen said that, while a mechanical door release resolves this problem, Tesla plans to “combine the two” to help reduce stress in what he called “panic situations.”
- He also added that “it’s in the cars now…The idea of combining the electronic and the manual one together in one button, I think, makes a lot of sense.” Franz said the muscle memory of reaching for the same button will be advantageous for children and anyone who is in an emergency.
Regarding the exterior door handle concerns in China:
- Von Holzhausen said Tesla is reviewing the details of the regulation and confirmed, “We’ll have a really good solution for that. I’m not worried about it.”
Franz von Holzhausen (from Tesla’s Robovan) on Tesla’s upcoming redesigned door handles: pic.twitter.com/lnaKve1SlJ
— Sawyer Merritt (@SawyerMerritt) September 17, 2025
The new Model Y already has emergency mechanical door release latches in the back, but combining them in future vehicles seems to be an ideal solution for other vehicles in Tesla’s lineup.
It will likely help Tesla avoid complaints from owners about not having an out in the event of a power outage or accident. It is a small engineering change that could be extremely valuable for future instances.
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