Tesla has unveiled a major leap in battery engineering with a newly published patent (US 2026/0196678 A1, July 9, 2026). Instead of cutting electrode foil into thousands of tiny tabs or fingers, Tesla now folds the foil’s edge into a continuous microscopic hem a kind of metal origami. As the cell is wound, each fold touches the next, creating a uniform full‑edge current path. This design removes entire families of tabbing, notching, laser‑cutting, debris‑handling, and exhaust equipment while preserving the electrical benefits of full‑edge current collection. It’s Tesla’s classic philosophy: the best factory step is the one you no longer need.
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