In producing the all-electric Taycan, Porsche has adopted a new innovation involving patches instead of plugs to cover structural holes.  

Holes in the vehicle structure are required so as to allow body cavities to be accessible during the painting operation.  After this the holes must be plugged because otherwise there is the potential for corrosion to occur. This is usually done by pushing plastic plugs into place, with approximately 150 plugs per vehicle, or some 3,600 per shift. In some instances, it requires that the operator has to work under the vehicle and pushed in the plugs overhead.

Porsche, working with supplier Tesa SE, has developed what it claims is an all-new approach, with the Taycan to be the first-ever vehicle to have sealing patches instead of plugs. These are robotically installed, saving time and labour. Patches also have the advantages of fitting all holes where as there needs to be four different sized plugs. The patches are also much flatter.

These new patches are being applied at the Porsche facility in Zuffenhausen and will soon be used at the paint shop in the company’s Leipzig plant.