Model 3 and Y use aluminum for the hood and door skins. Non-gigacasting models (currently only Model 3) use a lot of aluminum panels for the trunk and sub-trunk areas and for the trunk tub.
Thanks, I didn't know that. Is it the same for all factories or it varies?
Interesting point.
This is how the steel arrives at Starbase. Big rolls. That are then rolled out, cut and scored and folded and welded together.
From the beginning it was thought that the exoskeleton would be folded and that to fold it they might need to first score it and later back weld where they scored it. That would mean one large roll for the exoskeleton, but you are right about hood, doors, and bed.Interesting point.
I was in the clothing business for 20 years, and have watched many cutters go about their job.
Laying out the patterns in order to get most out of the meterage is key to a cutters job.
The side sails are easy enough, just reverse and cut them out of a rectangle.
The width of the SS roll could be just enough to cut out 2 doors with very little waste. Both sides of the bed can be laid out one on top of the other too.
The back gate, the front grill, could also fit length wise to fit the width of the roll.
Close enough. So far so good.
But then we get to the 'V' across the top of the doors, going across the front side seemingly cut out of one piece... and I have put a red arrow where its bent.
This bend at the red arrow needs to be welded, otherwise there is heaps of waste.
Apart from that, it looks pretty spectacular.. as far as wastage goes.
I'm going to guess the dimensions /design of pieces were also tweaked to get the most out of a sheet.
strange. I’m not at all a materials expert so no real surprise that I might be confused.
I believe you are correct that the sheet will have to be scored before being bent. It's too thick to bend without the scoring... Now, Elon said the doors would be 3mm thick but didn't exactly say that the rest of the body would be made from the same gauge of steel. Perhaps more normal bending process for every other bend but the doors. Hmm...
I'm not sure if Model 3 made in China are using gigacastings yet that would change some of the rear structure, but I don't think so. Other than that, all Model 3 are made in the Fremont factory. The door skins and hood will all be the same aluminum material. The gigacasting is also aluminum, but the structure is different in the rear. All Model Y from the 4 factories would have gigacastings.
Making a gentle curve around a roll is a LOT different than the relatively sharp curves of, say, a fender.
Yes, they are. https://evannex.com/blogs/news/tesla-s-megacasting-technology-is-catching-on-with-chinese-automakers
I suppose I just don’t appreciate thr “gentle” nature of the roll’s curve. Because, yes, you can somewhat “bend” a kitchen knife, butjust as you say you can’t bend a kitchen knife around a coffee cup - which is the shape of the steel rolls.
The stainless will likely come in rolls like this.
To get stainless to keep its bent shape permanently you need to get it over the point of plastic deformation. At that point it loses material strength as it deforms at the crease, but increases panel rigidity in the direction of the bend. The trick with bending is to try not to weaken the material whilst forming its shape. (Think of bending a fork backwards and forwards along the same point until it breaks)
