Tesla has taken another step toward reshaping the future of car production. The company has officially secured a new patent for its “Unboxed Process,” a manufacturing approach designed to increase efficiency, lower costs, and make its vehicles more affordable for a wider market.
At the core of this patent lies Tesla’s vision of moving beyond the century-old assembly line. Instead of building vehicles in one continuous, linear process, the Unboxed Process allows different parts of the car to be produced in separate sections, then brought together in a final assembly. This modular approach promises scalability for future mass-market models such as the Cybercab.
Tesla’s own description in the patent captures the spirit of this innovation: “The present disclosure relates to an automated system and method for assembling exterior vehicle parts to a vehicle assembly structure. The system utilizes an automated assembly cell with fixtures corresponding to each exterior vehicle part and references a global datum for precise alignment…The method improves assembly efficiency by compensating for substructure irregularities with an engineered adhesive gap and allows for continued assembly during adhesive curing through tacking operations.”
Instead of relying on conventional welding, Tesla plans to adopt advanced adhesives to join sections, minimizing errors while speeding up production.
The patent also emphasizes that vehicle parts could be pre-treated and painted before final assembly. As the filing notes: “In described examples, a modular vehicle architecture allows for the assembly of a vehicle in sections, which are then joined in a final assembly operation. This approach eliminates the traditional need for welding stamped panels and applying secondary coatings or painting at the full vehicle assembly level. Instead, the vehicle can be constructed in parts, with metal surface treatments like e-coating and painting applied beforehand.”
By doing so, Tesla not only reduces time but also enhances consistency in finishing, while avoiding many of the pitfalls of conventional production.
Tesla has made it clear that speed and cost-effectiveness are crucial as it prepares for the rise of autonomy and Robotaxis. Traditional methods, the company points out, can result in “compounding errors,” since “any slight misalignment or variance can add up.”