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Tesla has revealed a new patent that could make vehicle doors simpler and cheaper to build, continuing the company’s work on new vehicle designs that rethink how cars and trucks are manufactured.

According to a patent application published by the United States Patent and Trademark Office (USPTO) last week, Tesla wants to use a vehicle’s outer metal panels to provide strength and protection without needing as many parts underneath.

The idea is fairly simple. Most vehicle doors have an outer metal skin, along with additional metal supports hidden inside to make them strong enough to withstand impacts and everyday use. (via Patentlyze)

Tesla’s design would eliminate some of those extra supports by making the outer door panel strong enough to do much of the work itself.

Instead of attaching parts like window motors, door handles and hinges to separate supports, they could be mounted directly to the outer panel. The panel would also help protect occupants during a side impact, replacing some of the metal bars normally installed inside vehicle doors.

According to the patent filing, the panels could be made from a single sheet of steel or aluminum, with the option of leaving the exterior metal unpainted. By using fewer parts, Tesla says the design could reduce manufacturing costs and the amount of factory space needed to assemble vehicles.

The patent also describes how the doors would handle everyday stresses, including repeated opening and closing, twisting, and operating the windows.

While the filing includes drawings of the Cybertruck, Tesla does not name a specific vehicle that would use the design.

Although the application was published this month, the idea has been in development for several years. Tesla’s latest filing builds on earlier applications dating back to 2020.

You can read the full patent below.

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