Tesla appears to be ready to replace the wood trim in some of its vehicles
Tesla
Tesla appears ready to replace the natural wood trim in the Model 3 with non-woven fabric. The wood trim has long been a hallmark of luxury cars, and it is often associated with a classic and timeless aesthetic. However, the look has started to look dated in vehicles, especially as many manufacturers have moved to fake wood to reduce costs.
With this move, Tesla may be embracing a more modern and sustainable design approach. Non-woven fabrics are often made from recycled materials and are designed to be more durable and longer-lasting than traditional wood.
Cost Cutting
According to Chris Zheng, which one of our sources later confirmed, Tesla is replacing the wood trim in the Model 3, and possibly other models with a non-woven fabric that will be significantly cheaper to produce. The move is in line with the company's efforts to reduce the costs of its vehicles and make them more affordable and environmentally friendly.
The wood trim has been a notable feature of the Model 3 since its inception in 2017, but it is also a costly one. By removing it and replacing it with fabric, Tesla can reduce the vehicle's manufacturing costs.
This is in line with the upcoming Model 3 revamp which is rumored to be centered around cost-cutting and is expected to be available later this year.
Environmentally Friendly
It is important to note that the move away from wood trim is not just about cost-cutting. While wood is a natural and renewable resource, its production and harvesting can have significant environmental effects. In contrast, non-woven fabrics are often made of recycled materials, which can help to reduce the environmental impact of vehicle production.
Tesla has always been committed to sustainable and eco-friendly design practices, and this change is in line with that philosophy. By using recycled materials and reducing the environmental impact of vehicle production, Tesla is staying true to its mission of creating a more sustainable future.
Different Colors
While the use of non-woven fabric in place of wood trim is a significant change, Tesla may also be considering using different fabrics for different models or trim levels.
In the Model 3 Tesla changes the trim based on the interior color of the vehicle. However, with the use of fabric, Tesla could increase the number of options available. Tesla could offer carbon fiber trim for the performance model, or white/black fabric based on the interior of the vehicle.
More Customization
However, they could go one step further. One of the often-mentioned downsides of owning a Tesla is the lack of customizable options. If Tesla wants to provide more customization options for its customers, it could offer a variety of trim colors, much like you'd pick the exterior color of the vehicle.
Tesla could also change the interior trim to match the exterior color of the vehicle to offer a more cohesive look.
Which Models This Will Apply To
Tesla has often shared as many parts as possible between their models, especially 'sibling' vehicles such as the Model 3 and Model Y. While the Model 3 vehicle is the one spotlighted in news regarding Tesla's revamp, it's likely that many of the features that are being talked about for the Model 3 will also carry over to the Model Y.
While the Model S and Model X also include wood trim on the dash, doors and center console, it's not clear whether Tesla will take a similar approach to their luxury line of vehicles.
The decision to replace wood trim with non-woven fabric in Tesla's vehicles is a multi-faceted one. While it will help reduce costs and make their cars more affordable, it is also part of a broader trend toward sustainable design practices.
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Tesla’s Cybertruck has officially earned a 5-Star Safety Rating from the NHTSA—an impressive achievement given the vehicle’s design. The achievement demonstrates Tesla’s engineering prowess. As one engineer points out, it wasn’t an easy feat.
Interestingly, the NHTSA only recently disclosed the results, despite the crash tests being completed a while ago. According to Lars Moravy, Tesla’s VP of Vehicle Engineering, the team had been aware of the 5-star rating for quite some time. While the reason for the delay remains unclear, now that the results are public, Tesla’s engineers can finally share how they achieved the rating.
Crumple Zones
Wes Morril, the Cybertruck’s Lead Engineer, wrote about the crash test video on X recently, addressing the claims that the Cybertruck doesn’t have a crumple zone. He also posted a side-by-side video (below) of the engineering analysis and the crash test itself.
Engineered Crash Safety
There’s a lot of engineering precision at play when a Cybertruck is involved in a crash. Unlike traditional crash structures that rely on crash cans and collapse points, the Cybertruck’s front gigacasting is designed to absorb and redirect impact forces in a highly controlled manner.
It all starts with the bumper beam, which crushes within the first few milliseconds of a high-speed impact. At the same time, the vehicle’s sensors rapidly analyze the crash dynamics and determine the optimal deployment of safety restraints, including airbags and seat belt pre-tensioners. These split-second actions are crucial in keeping occupants safe.
As the crash progresses, the vehicle’s structure deforms in a carefully engineered sequence. The drive unit cradle bends, directing the solid drive unit downward and out of the way, allowing the gigacasting to begin absorbing impact forces.
The casting crushes cell by cell, methodically dissipating energy in a controlled manner. This gradual deceleration reduces the g-forces transferred to occupants, making the crash much less severe. As the gigacast begins crushing, the safety restraints are deployed.
As Wes points out in his post - you can see how accurate the virtual analysis and modeling were. The video shows the simulated crash side by side with the real-life crash test and they’re almost identical. All that virtual testing helps provide feedback into the loop to design a better and safer system - one that is uniquely different than any other vehicle on the road.
All the armchair experts claimed the Cybertruck has no crumple zone and I get it, the proportions seem impossible. It was a tough one and there is a lot of engineering that went into it. Let me break it down for you:
Tesla has pioneered the use of single-piece castings for the front and rear sections of their vehicles, thanks to its innovative Gigapress process. Many automakers are now following suit, as this approach allows the crash structure to be integrated directly into the casting.
This makes the castings not only safer but also easier to manufacture in a single step, reducing costs and improving repairability. For example, replacing the entire rear frame of a Cybertruck is estimated to cost under $10,000 USD, with most of the expense coming from labor, according to estimates shared on X after high-speed rear collisions.
These insights come from Sandy Munro’s interview (posted below) with Lars Moravy, Tesla’s VP of Vehicle Engineering, highlighting how these advancements contribute to the improvements in Tesla’s latest vehicles, including the New Model Y.
However, with the new Model Y, Tesla has decided to go a different route and eliminated the front gigacast.
No Front Casting
Tesla’s factories aren’t equipped to produce both front and rear castings for the Model Y. Only Giga Texas and Giga Berlin used structural battery packs, but these were quickly phased out due to the underwhelming performance of the first-generation 4680 battery.
Tesla has gone back to building a common body across the globe, increasing part interchangeability and reducing supply chain complexity across the four factories that produce the Model Y. They’ve instead improved and reduced the number of unique parts up front to help simplify assembly and repair.
There is still potential for Tesla to switch back to using a front and rear casting - especially with their innovative unboxed assembly method. However, that will also require Tesla to begin using a structural battery pack again, which could potentially happen in the future with new battery technology.
Rear Casting Improvements
The rear casting has been completely redesigned, shedding 7 kg (15.4 lbs) and cutting machining time in half. Originally weighing around 67 kg (147 lbs), the new casting is now approximately 60 kg (132 lbs).
This 15% weight reduction improves both vehicle dynamics and range while also increasing the rear structure’s stiffness, reducing body flex during maneuvers.
Tesla leveraged its in-house fluid dynamics software to optimize the design, resulting in castings that resemble organic structures in some areas and flowing river patterns in others. Additionally, manufacturing efficiency has dramatically improved—the casting process, which originally took 180 seconds per part, has been reduced to just 75 seconds, a nearly 60% time reduction per unit.
Advancements in die-casting machines and cooling systems have allowed @Tesla to dramatically reduce cycle times and improve dimensional stability. pic.twitter.com/WB5ji67rvV
Tesla’s new casting method incorporates conformal cooling, which cools the die directly within the gigapress. Tesla has been refining the die-casting machines and collaborating with manufacturers to improve the gigapress process.
In 2023, Tesla patented a thermal control unit for the casting process. This system uses real-time temperature analysis and precise mixing of metal streams to optimize casting quality. SETI Park, which covers Tesla’s manufacturing patents on X, offers a great series for those interested in learning more.
The new system allows Tesla to control the flow of cooling liquid, precisely directing water to different parts of the die, cooling them at varying rates. This enables faster material flow and quicker cooling, improving both dimensional stability and the speed of removing the part from the press for the next stage.
With these new process improvements, Tesla now rolls out a new Model Y at Giga Berlin, Giga Texas, and Fremont every 43 seconds—an astounding achievement in auto manufacturing. Meanwhile, Giga Shanghai operates two Model Y lines, delivering a completed vehicle every 35 seconds.
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