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Some Explanations About Materials ALSETTE Uses to Manufacture Replacement Parts for Tesla Vehicles (2023)

We understand that you may be searching for a new supplier for your metal replacement parts, and we’re glad to have caught your attention.

We know that there may be some concerns regarding our Tesla aftermarket parts, and the materials used is one of them.

That’s why we’ve written this article to address your material-related questions and hopefully provide you with the information you need.

We know that Tesla has made a lot of efforts in using lightweight materials, and we’ll focus on the materials used in the Model 3 and Model Y. (click to see details at Tesla’s official website)

These two models have the highest sales volume, which aligns with our goal of producing aftermarket parts that have a high market demand.

Typically, the materials used in our aftermarket parts production are the same as those used by Tesla, the original manufacturer.

Only in cases where customers have special material requirements for certain parts do we customize them accordingly.

Tesla Model Y white body

Since our company – ALSETTE is solely dedicated to the development and production of sheet metal parts, we mainly use three materials based on those used in Model 3 and Y: high-strength steel, soft steel, and aluminum alloy.

What is high-strength steel?

High-strength steel is a type of metal that’s stronger and more durable than regular steel, which makes it a great choice for car parts.

It can withstand more force and pressure without deforming or breaking, which makes it safer for drivers and passengers in the event of an accident.

Besides, compared to conventional steel, high-strength steel can provide higher strength and stiffness at the same thickness, allowing for the use of thinner materials in vehicle manufacturing and thus reducing the weight of the vehicle.

These high-strength steels are usually classified into two categories: Advanced High-Strength Steels (AHSS) and Ultra High-Strength Steels (UHSS).

Advanced High-Strength Steels (AHSS)

AHSS is a type of steel that is designed to provide high strength and ductility. It is often used in automotive manufacturing to improve the safety and structural integrity of the vehicle.

It is made by combining low-carbon steel with small amounts of other metals, such as manganese, chromium, and boron, which helps to increase its strength.

At Tesla, AHSS’ tensile strength is between 550~1200MPA. In Model 3, this material accounts for 38.3% of the total.

Ultra High-Strength Steels (UHSS)

UHSS is even stronger than AHSS and is often used in critical safety components such as side impact beams and B-pillars.

It is made by adding even greater amounts of elements such as manganese, silicon, and boron to low-carbon steel, which increases its strength while maintaining ductility.

At Tesla, UHSS’ tensile strength is over 1300MPA. 18.7% of Model 3 uses UHSS.

What is soft steel?

Soft steel is a type of low-carbon steel that is relatively soft and malleable, so it is generally easy to form and weld.

It contains less than 0.3% carbon and is often used in applications where the steel must be formed into a specific shape, such as in automotive body panels and structural components.

About 12.5% body of Model 3 is manufactured of soft steel.

ALSETTE semi-finished trunk lids for Tesla Model 3, made of high-strength steel.

What is aluminum alloy?

aluminum alloy is a type of metal that is made by mixing aluminum with other elements such as copper, zinc, or magnesium to improve its mechanical and chemical properties.

Tesla uses various types of aluminum alloys in their vehicles, including the commonly used 6xxx series and 7xxx series.

These aluminum alloys are lightweight and offer high strength and excellent corrosion resistance, making them ideal for electric vehicles’ applications.

The 6xxx series is often used in exterior body panels, while the 7xxx series is typically used in structural components such as the chassis and suspension.

ALSETTE front bumper reinforcement rail extension for Model 3, uses aluminum alloy and steel.

Besides, Tesla has applied for several aluminum alloy patents, including the “Die Cast Aluminum Alloys for Structural Components” and the “ALUMINUM ALLOYS FOR DIE CASTING”.

Tesla’s patent for its aluminum alloy on Oct. 28, 2021

These patents describe unique aluminum alloy formulations that are specifically designed for use in the automotive industry, with the goal of improving strength, durability, and corrosion resistance while reducing weight.

These alloys are typically used in the production of body components, such as doors, hoods, and fenders, as well as structural components, such as frames and suspension parts.

The patents highlight Tesla’s commitment to innovation and continuous improvement in the development of its electric vehicles.

Tesla says that about 30.5% of Model 3 is built with aluminum alloy.

A picture made by Tesla, which showed at Tesla’s “T-Talk” roadshow at Shenzhen Tesla center, China.

It is a diagram that illustrates the structure of the Model 3 car body.

The framework is color-coded with red, orange, blue, and white, indicating ultra-high-strength steel (≥1300 MPA), high-strength steel (550-1200 MPA), soft steel, and aluminum alloy, respectively.

The proportion of ultra-high-strength steel and high-strength steel reaches about 56%.

Now that we’ve introduced these three types of materials, you may be wondering how to connect them to the manufacturing materials mentioned on our product page, which only lists iron and aluminum.

This is a great question, and I’m here to answer it.

Aluminum in our product description actually refers to aluminum alloy, while iron refers to steel, which includes AHSS, UHSS, and soft steel.

A front crush can for Model Y. Made of both aluminum alloy and steel.

Each component uses a different type of material, and this involves many knowledge points related to mold development and product stamping processes, which I cannot explain one by one in this article.

I’ll write more articles in the future to introduce related knowledge.

Well, this article is about to end, and I really love Tesla. Let’s end this article with some praise for Tesla.

Tesla Inc. is a remarkable company, much like Apple in the world of smartphones, it has brought about revolutionary changes in the automotive industry.

It is a bold innovator, evident in its use of lightweight materials. Tesla strikes a fine balance between electric car safety and energy efficiency, all while reducing manufacturing costs.

There is much we can learn from Tesla.

Thank you very much for reading our article patiently, and good luck to you.

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Hi, I'm Lina. Co-founder of ALSETTE.
Nice to meet you.
We focus on manufacturing metal exterior aftermarket parts for Tesla from China.
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