Tesla files suit after faulty ‘falcon doors’ cause a delay on the Model X

By Stephen Edelstein Updated January 22, 2016

Tesla Model X — Image used with permission by copyright holder

Roof-hinged “falcon doors” are one of the Tesla Model X’s standout features, but may have also been a big contributor to the production delays that pushed the electric crossover’s launch back almost two years. Now, Tesla is blaming a former supplier for what it calls a faulty design.

The carmaker filed a lawsuit against German supplier Hoerbiger Automotive Comfort Systems in the U.S. District Court of Northern California. The suit alleges that Hoerbiger misrepresented its ability to design the “falcon doors,” forcing Tesla to switch to a new supplier at the last minute, reports The Wall Street Journal (subscription required).

Tesla claims it paid Hoerbiger to design hydraulic devices to lift the doors, after the company won a competition for the contract. But when the German firm delivered prototypes, they leaked oil and caused doors to sag, according to the lawsuit. Tesla claims the company is now seeking additional payments it is not entitled to. It paid Hoerbiger $3 million for the work it did, and does not believe it owes the supplier any more money.

In May 2015, Tesla gave up on Hoerbiger, and hired another supplier to design door-lifting mechanisms for the Model X, the lawsuit says. It claims Tesla “incurred millions of dollars in damages,” including the cost of “re-tooling the entire vehicle” to accommodate the new supplier’s design. Tesla claims it also had to pay the new supplier a premium to get the job done quickly.

Tesla certainly didn’t need any problems as it worked to get the Model X ready for production. The electric crossover was first shown in January 2012, and Tesla originally hoped to put it on sale in December 2013. But various issues meant the first vehicles weren’t delivered to customers until the end of September 2015. Very few units have likely been delivered since then, as Tesla is still ramping up production.

Topics

Stephen Edelstein

Contributing Editor

Stephen is a freelance automotive journalist covering all things cars. He likes anything with four wheels, from classic cars…

Cars

The Tesla Model Y is far from my favorite EV, but I’m pretty close to buying one

Tesla Model Y One Millionth Car

I may finally be on my way toward buying my first EV. Sure, I've tested dozens of electric car models over the years, but despite that (or perhaps because of it), I have yet to buy one. But my family is growing, and my wife and I aren't so sure about carting our future kids around in an aging car that lacks the safety features of modern vehicles.

Because of the fact that we're expecting our kid in January, we have a bit of a deadline. So what are we leaning toward? Well, despite the fact that it's far from my favorite EV, we may actually end up just getting a Model Y.
Timing makes a difference
If the baby was coming along in a year's time, things might be completely different. There are a few reasons for that.

Cars

Tesla Model 3 vs. Hyundai Ioniq 6: Which electric sedan is best?

Front three quarter view of the 2023 Hyundai Ioniq 6.

There are finally some more electric sedan options. For years, the Tesla Model 3 was really the only good electric sedan that comes at a reasonable price -- until, Hyundai recently launched the Ioniq 6. The Ioniq 6 certainly takes some cues from the larger Ioniq 5, but is smaller and sleeker, with a design seemingly inspired by the Porsche 911.

But the Tesla Model 3 is still clearly an excellent option for those looking for an electric car, and who don't want a larger crossover. Which is better? Here's a look.
Design
The exterior design of the Tesla Model 3 and Hyundai Ioniq 6 is quite different. If you've seen a Tesla car before, then you'll immediately recognize the Model 3 -- it looks largely like a slightly different version of every other Tesla (except the Cybertruck).

Cars

Tesla launches more affordable Model S and Model X, but there’s a catch

A 2021 Tesla Model S.

Tesla has launched more affordable versions of its Model S sedan and Model X SUV in the U.S. and Canada, though they come with shorter driving ranges. Deliveries of the new vehicles will begin next month.

The new Model S "standard range" vehicles cost $78,490 and offer a range of up to 320 miles (515 kilometers), which is considerably shorter than the pricier regular dual-motor and tri-motor Plaid versions that feature a range of 405 miles and 396 miles, respectively, Reuters reported.