Tesla is known to constantly innovate, from the software of its cars to the chemistry of the batteries that power them. And a recently published patent application serves as proof, Tesla's innovations reach all the way down to the metals used to make 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 strong 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, which would allow the company to improve its production costs.

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

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

Tesla noted that many structural components made from aluminum alloys today may require processes such as heat treatment, which improves strength, hardness, ductility and corrosion resistance. These processes ensure quality, but also require large capital expenditures, extended processing times and potential yield losses.

Because of this, Tesla has thought it would be preferable to produce aluminum alloys with a high yield strength and sufficient ductility, without the need for heat treatment.

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