Tesla has a new U.S. patent. It covers the “Unboxed Process.” This way of building cars aims to make vehicles cheaper and manufacturing more efficient. Tesla said it will use the process for future large-scale models like the Cybercab. They first talked about this new method at Investor Day 2023.
How the process works
Tesla doesn’t put cars together in a long line anymore. Now the front, rear, and underbody are built as separate modules. These parts get painted before coming together. Final assembly happens in one step. This setup is meant to cut down on mistakes from misaligned parts. It also lets workers and robots focus on each module for better results.
Robots prepare each section. They use fixtures and reference points to align them. Glue is used to hold parts in place, not welding. Robots tack the sections together.
The glue cures while the rest of the work continues. This method improves speed and lets the factory keep moving without stopping for drying or errors.
Tesla uses adhesives to join modules instead of welding. This change cuts out hundreds of steps.
It uses less space and takes less time to build each car. If a small problem happens in one module, it doesn’t slow down the whole factory.
Benefits of the Unboxed Process
Tesla says this method can cut factory space by around 40% and lower production costs by about 50%. Production also speeds up because each team works on a different module at the same time. The Gigafactory in Texas is already using parts of this process. The Cybercab robotaxi will use this approach next.
The patent builds on things Tesla already does, like Gigacasting and putting battery packs right into the car’s frame. The updated process includes prepainting and metal treatments before final assembly. Using glue helps fill small gaps, so uneven parts don’t create weak spots.
Tesla wants to produce more cars, faster, and at lower cost. They’re aiming for big growth as they expand new services like Robotaxi, which demand lots of vehicles. The company expects these changes to cut factory costs and make new models scaled for a wider market. Testing for the process started at the Gigafactory in Texas. The first target is the Cybercab, a two-seat, driverless vehicle for ride-hailing.
Tesla says this process could build a Cybercab in around 5 seconds. They believe it sets a new standard for how electric cars can be made fast and at low prices. However, Tesla’s “Unboxed Process” could make it cheaper and faster to build electric cars. If it is successful, other car companies might follow this way of working.
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