Tesla trades paint for durability on mirror caps
A design change to side mirror caps cuts costs while improving resistance to scratches and brush contact.
Tesla made a manufacturing change to side mirror caps that achieves a rare combination: lower cost and better durability in one move. The caps were originally painted, which looked good when new but proved vulnerable to scratching from everyday hazards like brush contact while driving.
Engineers switched the mirror caps to the same grained plastic surface already used on the vehicle's fenders, according to the post. The textured plastic is significantly more resistant to damage than the painted finish. The change also eliminates the need for the paint process entirely, reducing manufacturing cost.
The update creates a secondary benefit: the mirror caps now match the finish of other exterior plastic trim, creating a more cohesive appearance across the vehicle.
"Sometimes you can take out cost AND make the product better. It's rare, but with focus, it can happen. The side mirror cap was initially painted. It looked good new, but the paint was too easy to scratch. For example driving through brush, since there was no other paint to worry about! We found the plastic with a grained surface on the fenders was much more durable, so we moved to that execution"— X · @wmorrill3