Approved Gas Metal Arc (GMA) Welders and Welding Wire

Describes the approved GMA welders and welding wire for structural repairs on Tesla vehicles.

Use only approved welders for welding during structural repairs on Tesla vehicles.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Using non-approved welders might compromise the integrity of the repair and vehicle safety.
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Warning
To maintain vehicle crash integrity, use only the welding wires specified in Approved GMA Welding Wires for Structural Repairs to perform GMA welding on Tesla vehicles.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Failure to follow all welding safety precautions, including the use of personal protective equipment, could result in serious injury or property damage. Only technicians who have completed Tesla’s approved welding training are authorized to weld structural components on Tesla vehicles.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
To ensure the safety of the technician and proper use of the welder, only technicians who have completed the appropriate training for the approved welder are authorized to weld structural components on Tesla vehicles.

Approved Gas Metal Arc (GMA) Welders

The GMA (gas metal arc) welders listed below are approved for aluminum and steel GMA welding during structural repairs on Tesla vehicles:

Table 1. Approved GMA Welders
Manufacturer GMA Welder Approved for
Car Bench Sound MIG 2060/md (Model 301)
  • Model S (All)
  • Model X (All)
  • Model 3 (All)
Jaguar Sound MIG 2060/md (Model 302)
  • Model S (All)
  • Model X (All)
  • Model 3 (All)
Car-O-Liner CMI273 Pulse Twin All vehicles
CMI300 Pulse Duo All vehicles
CMI300 Pulse Trio All vehicles
Cebora Jaguar Sound MIG 2060/MD (Model 302) All vehicles
Jaguar MIG E200/MD (Model 321) All vehicles
Sound MIG 2060/MD (Model 301) All vehicles
Sound MIG 2740/T Star Pulse (Model 307) All vehicles
SynStar 330TC (Model 386) All vehicles
SynStar Twin 270T (Model 344) All vehicles
Chief MultiMig 521 All vehicles
MultiMig 522 All vehicles
MultiMig 525 All vehicles
MultiMig 621 All vehicles
MultiMig 721 All vehicles
MultiMig 822 All vehicles
ELMA-Tech MIDI MIG 300/800 All vehicles
Fronius TransPuls Synergic 2700 All vehicles
TransPuls Synergic 2700 CMT All vehicles
TPS 270i C Pulse All vehicles
TPS 320i C All vehicles
TPS 320i C Pulse All vehicles
TPS 320i Pulse, Dual Head All vehicles
GYS AutoPulse 220-M3 All vehicles
NeoPulse 300-T2 All vehicles
P3 GYS Auto All vehicles
Lincoln Electric Power MIG 350 MP (K4663-1) All vehicles
Power MIG 255 XT (K2701-2) All vehicles
Miller MillerMatic 255 Auto All vehicles
Millermatic 350P All vehicles
PRO SPOT SP-1 All vehicles
SP-2 All vehicles
SP-5 All vehicles
SP-5 DP All vehicles
SP-5.3 All vehicles
Spanesi Q5.2 INVERTER All vehicles
Q5.2 ONE INVERTER All vehicles
Wieländer + Schill InvertaPuls IP4-3 All vehicles
InvertaPuls IP6-2 All vehicles
InvertaPuls IP7-2 All vehicles

Approved GMA Welding Wires for Structural Repairs

Describes approved GMA welding wires for use in structural repairs.

Use only approved GMA (gas metal arc) welding wire for structural repairs on Tesla vehicles.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Failure to follow all welding safety precautions, including the use of personal protective equipment, could result in serious injury or property damage. Only technicians who have completed Tesla’s approved welding training are authorized to weld structural components on Tesla vehicles.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
To maintain vehicle crash integrity, use the welding wires specified in this document to perform GMA welding on Tesla vehicles.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Before GMA welding, make sure that the structural adhesive is dry to the touch.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Before GMA welding, perform a test weld using material of the same gauge and type to make sure that the welding equipment settings produce a satisfactory joint.

Use only approved the GMA welding wires listed below for structural repairs on Tesla vehicles.

Material Approved Welding Wire Part Number Thickness
Aluminum ER4145 AlcoTec: 414505047

Lincoln Electric: ED037457

Tesla: 1022767-00-A

 1.2 mm diameter
Mild Steel ER70S-6 (any) Vendor-specific Any diameter
Bohler Union X96 Pro-Spot: 50-7040 Rev. B
Eagle-Arc 980X Pro-Spot: 50-7040 Rev. C
Titan Technology 5029x96 Titan Technology: EQ-5029X96
High-Strength Steel Bohler Union X96 Pro-Spot: 50-7040 Rev. B .8 mm diameter
Eagle-Arc 980X Pro-Spot: 50-7040 Rev. C
Titan Technology 5029x96 Titan Technology: EQ-5029X96
Ultra High-Strength Steel Bohler Union X96 Pro-Spot: 50-7040 Rev. B .8 mm diameter
Eagle-Arc 980X Pro-Spot: 50-7040 Rev. C
Titan Technology 5029x96 Titan Technology: EQ-5029X96
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Note
Part numbers were current at the time of publication. Use the revision listed or later, unless otherwise specified in the Parts Manual.
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Note
All Tesla-approved welders use 5 lb spools of welding wire.

For information on the material used for specific body components on Tesla vehicles, refer to Body Structure Materials and Allowed Operations.