Tesla plans direct-injected PU paint to accelerate Cybercab production

Tesla plans to adopt a new manufacturing technique for its upcoming Tesla Cybercab that involves injecting polyurethane (PU) paint directly into plastic body panels during the moulding stage, removing the need for a traditional automotive paint shop.

According to the company’s vice-president of vehicle engineering, Lars Moravy, Tesla aims to incorporate colour into the plastic panels as they are formed instead of applying paint in a separate finishing step.

This method essentially merges moulding and finishing into a single operation. Rather than stamping metal panels and passing them through multiple coating and curing processes, Tesla intends to mould exterior panels from plastic and inject a polyurethane coating directly during production.

The concept resembles an in-mould coating (IMC) process, where polyurethane paint is introduced into the mould after the plastic substrate forms. The coating bonds to the surface while the part is still warm, creating a thin layer integrated with the panel rather than a conventional sprayed finish applied on top.

Tesla believes the technology could streamline vehicle production by eliminating one of the most complex stages of manufacturing. Traditional automotive paint shops require significant factory space and are among the most energy-intensive and highly regulated areas of vehicle assembly due to solvent emissions and curing requirements.

If implemented on a large scale, the direct-injection method could reduce capital investment, factory footprint and production time. Because colour is integrated into the material itself, minor scratches may not expose a different underlying layer, potentially lowering the need for repainting or refinishing.

The Cybercab will also be produced using Tesla’s “unboxed” manufacturing approach. Unlike conventional assembly lines that build vehicles sequentially, this process allows different vehicle sections to be constructed simultaneously before being brought together. The method is designed to improve accessibility for workers and robots while enabling more engineers to work on the vehicle at the same time, increasing production efficiency.

The two-seat autonomous vehicle, intended for Tesla’s future robotaxi network, is currently under development, with production targeted for the latter half of the decade.

However, both the manufacturing process and production schedule are yet to be fully confirmed. Tesla has previously announced technologies that were later delayed or significantly revised, so the commercial viability of the direct-injected PU paint process will only become clear once the vehicles reach series production.

Source: PU Magazine