Why Tesla Aluminum Doors Are So Much Harder to Repair with Paintless Dent Repair (PDR)

By Eddie Martin · Updated November 10, 2025 · San Diego, CA

Below you’ll find both technical line-art diagrams (best for explaining technique) and full‑color graphics (best for consumer comparison). I’ve placed each where it supports the copy most.

Why Tesla Aluminum Doors Are Harder for PDR

High-strength aluminum with pronounced springback.
Stamping tension makes initial pushes feel “dead.”
Thin outer skin amplifies tiny errors and can oil‑can.
Limited leverage thanks to sparse/braced internals.
Paint sensitivity requires careful temperature control.

Technical Diagrams

Line-art: Tesla door structure, PDR leverage, springback chart — Line-art: cross‑section, leverage on a crown, and springback curve placed here near the technical explanation for maximum clarity.

Full‑Color Consumer Comparison

This shows a typical non‑PDR body shop process (sand → fill → prime → repaint) versus true PDR.

Full‑color infographic comparing PDR vs. conventional body shop steps and outcomes — Full‑color graphics: ideal for customers—what stays OEM with PDR vs. what changes with conventional repair.

Feature	PDR	Conventional Body Shop
Keeps factory paint	✔	✖
Uses fillers (Bondo)	✖	✔
Needs repainting	✖	✔
May affect Carfax	✖	✔
Typical repair time	Faster	Slower
Total cost	Usually lower	Usually higher