Tesla is known for constantly innovating, from the software in its cars to the chemistry of the batteries that power them. And a recently published patent application proves that Tesla's innovations extend to the metals used to manufacture its cars. By using aluminum alloys developed by the company, for example, Tesla could usher in a new class of electric cars that are incredibly durable and cheaper to produce.

The patent, titled "Die Cast Aluminum Alloys for Structural Components,"describes an aluminum alloy that is extremely strong and ductile. The aluminum alloy would not require further processing, allowing the company to improve its production costs.

In the patent description, Tesla points out that commercial cast aluminum alloys, such as those used in electric vehicle chassis, must be both strong and ductile.

If manufactured correctly, castings can be produced quickly and reliably, and should retain their structural properties well. However, alloys that cannot be cast properly result in hot tearing, which causes problems.

Tesla pointed out that many structural components made from aluminum alloys may currently require processes such as heat treatment, which improves strength, hardness, ductility, and corrosion resistance. These processes ensure quality, but also require significant capital expenditure, long processing times, and potential yield losses.

For this reason, Tesla has decided that it would be preferable to produce aluminum alloys with a high elastic limit and sufficient ductility, without the need for heat treatment.

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