Tesla has recently been granted a new patent for its innovative “Unboxed Process” of manufacturing, aimed at increasing affordability for customers by improving efficiency during the manufacturing stage. This approach is part of Tesla’s broader strategy to make a significant impact from the initial production phase to the final product, particularly with their upcoming vehicles. The Unboxed Process was first introduced by Tesla during its “Investor Day” in 2023, highlighting a shift from traditional assembly lines to enhance efficiency, cost-effectiveness, and scalability, especially for mass-market models like the Cybercab.
The Unboxed Process incorporates Tesla’s existing technologies in automotive manufacturing, such as Gigacasting and structural battery integration, along with more efficient “post-manufacturing” processes like pre-painting. The main advantages of this patented process include an automated system for assembling exterior vehicle parts with precise alignment, compensating for substructure irregularities, and allowing for continued assembly during adhesive curing through tacking operations.
Instead of traditional welding methods, Tesla intends to use adhesives for bonding in the manufacturing process. The modular vehicle architecture allows for the assembly of vehicles in sections, eliminating the need for welding stamped panels and applying secondary coatings or painting at the full vehicle assembly level. This approach streamlines the manufacturing process, enabling Tesla to build more vehicles at a faster rate and a lower cost, which is crucial as the company addresses autonomy and the increasing demand for Robotaxis.
The Unboxed Process aims to reduce errors by focusing on efficiency and build quality, mitigating issues commonly associated with traditional linear manufacturing processes. By adopting this innovative approach, Tesla anticipates a smoother and more cost-effective manufacturing process that aligns with the company’s commitment to innovation and sustainability.