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Tesla’s 2021 Model 3 has undergone some key under-the-hood refinements—particularly in the front trunk (frunk) design and the vehicle’s thermal management system. These updates don’t just improve robustness and reliability. They have a real impact on cost and performance, especially in extreme weather conditions. In this teardown review, Munro & Associates takes a closer look at the changes that make the 2021 Model 3 a better-engineered machine, with special attention to its improved cooling system, updated clips, and overall build quality.
Clip Failures and Design Evolution
We began with some hands-on inspection of the frunk area. The team immediately noticed an issue common to many earlier Tesla teardowns—broken plastic clips, often referred to as “Christmas trees.” These fasteners are critical for keeping panels and internal components secure, but they’ve historically been a weak point. In the past, these clips were fragile and prone to snapping during removal or even regular use.
However, in this 2021 iteration, some of these concerns appear to have been addressed. While one or two clips were still broken or missing, others held up significantly better than before. It wasn’t the Munro team’s favorite snap fit, admittedly. At the very least, however, it wasn’t broken—an improvement over the previous iteration our team reviewed. These changes point to incremental yet important progress in lean design. Each tiny improvement helps reduce warranty claims and service costs, and enhances the customer’s overall experience.
Stronger Frunk Structure
Another highlight of the teardown is the disappearance of a previously noted “thin wall” in the frunk assembly. This design weakness had been criticized in earlier versions for potentially compromising structural integrity. The new 2021 version replaces that with a more robust structure, showing thoughtful attention to manufacturing and real-world durability. This enhancement contributes to the Model 3’s reputation for engineering quality and continues Tesla’s tradition of continuous improvement.
From a cost perspective, even small updates like this make a significant difference. Stronger parts reduce failure rates, lower production complexity, and improve manufacturability—hallmarks of lean manufacturing. Munro’s commentary affirms this: “All these little features make a big difference at the end of the day as far as cost.”
Cooling System Overhaul
Perhaps the most significant update revealed during this inspection is the cooling system. Although full testing is still pending, preliminary user reports already point to a striking improvement. According to Munro, “I’ve already gotten dozens of people calling me back saying they have an old Model 3 and a new Model 3, and this thing is outperforming it by about 30%.”
That’s a dramatic leap—especially in cold weather, which is historically difficult for electric vehicles due to battery and cabin heating demands. Tesla’s updated cooling architecture appears to manage thermal loads more efficiently, which means faster cabin warm-up, less energy consumption, and extended range in adverse climates.
This aligns with broader EV industry trends emphasizing thermal efficiency. From battery longevity to interior comfort, a high-performance cooling system can significantly enhance user experience and vehicle reliability.
Engineering Verdict
Munro’s team offers an unusually positive verdict. “Everything I see here is 100% good engineering,” they declare—high praise from a group known for their rigorous scrutiny of automotive design.
While the teardown didn’t cover every internal element in detail, the early findings suggest Tesla has taken real strides in improving product quality in subtle but important ways. From sturdier fasteners to a dramatically better thermal system, these tweaks reflect a maturing design and a brand steadily moving toward optimization and refinement.
Why This Matters for the Industry
Tesla’s decision to quietly improve under-the-hood components speaks volumes about how it approaches iteration. Unlike traditional automakers that rely heavily on model-year refreshes and platform overhauls, Tesla adopts a more software-like mindset: constant updates, agile adjustments, and customer-informed design changes.
The enhanced cooling performance also highlights Tesla’s response to real-world data. Cold weather performance has been a known weakness for many EVs—not just Tesla’s. The fact that the Model 3 now outperforms older versions by such a wide margin shows how important thermal system design is to the future of EV adoption in colder climates.
For engineers and industry observers, this underlines the importance of not just flashy innovations, but also the incremental changes that reduce failure rates, improve serviceability, and enhance total cost of ownership.
Model 3 Cooling System Takeaways
- Snap-fit Design Matters: A broken clip might seem minor, but consistent failure of fasteners can compromise serviceability and customer trust. Reinforced clips and better materials contribute to real-world reliability.
- Thermal System Efficiency Is Key: A 30% improvement in thermal performance, especially in cold weather, translates directly into higher range and better user experience. This positions the Model 3 more favorably against competitors in cold-weather markets.
- Continuous Improvement Pays Off: The 2021 Model 3’s changes aren’t flashy, but they’re impactful. This is how smart OEMs cut costs and improve product performance over time—without marketing every tweak.
- Customer Feedback Loops Work: Tesla’s ability to rapidly implement changes based on user reports gives it a huge advantage in iterative product development. This is especially important in areas like HVAC and battery management systems.
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