Tesla's Unboxed Manufacturing Process — How It Works & Why - CleanTechnica

Tesla has been granted two new US patents for its innovative "unboxed manufacturing process," which promises to revolutionize automobile production by enabling faster assembly with fewer workers, lower costs, and smaller factory footprints. Unlike traditional auto manufacturing—where a vehicle’s body is assembled as a single "box" into which all systems are later installed—the unboxed process involves completing major sub-assemblies, such as the dashboard or front end, separately before joining them. This modular approach allows different components to be built in parallel rather than sequentially on a single assembly line, reducing bottlenecks and increasing efficiency. A key advantage of the unboxed method is its potential to halve production costs and factory size while dramatically speeding up manufacturing. The process also addresses common pain points like corrosion resistance and painting: instead of treating and painting the entire body as one unit with attached doors and panels, these parts are treated and painted separately and then fitted to the body. This reduces complexity and streamlines interior installation. Overall, Tesla’s