That’s why the Porsche Taycan has 143 holes

New manufacturing process for the electric Porsche
106 holes in the Taycan are glued with Tesa

143 holes sift through the body of the Porsche Taycan and are later – no joke – glued with Tesa. Find out why here.

There are things in everyday life that we are quite happy to have holes in. A sieve, for example, salt shakers or the sink. The body of your car is not usually one of them. But, as you’ll learn in a moment, that’s a pretty superficial observation in the case of the Porsche Taycan.

106 of 143 holes in the Taycan’s body are glued with tape.

You don’t even get to see the holes in the body, but the painters at the factory do. What’s more, the employees there also have to close the holes again. The corrosion protection for the cavities flows into the designed openings. These cavities then have to be sealed watertight. These are steps that are crucial to the durability of the car. What is new here is that the holes in the Taycan are now no longer plugged, but glued. This is a technique that has not been used on any other production vehicle to date.

106 Tesa adhesive pads

In fact, Tesa SE is the Zuffenhausen company’s cooperation partner here. However, no classic adhesive tape is used for sealing, but special adhesive pads that are automatically applied to 106 of the 143 openings. But can such adhesive pads really withstand all the material stresses that are to be expected in such a high-performance sports car? What’s more, explains Dirk Pfaffe, planning manager for painting processes at Porsche: “The adhesive pads last longer than the life of a car.”

Porsche Taycan Lackierung Fertigung Produktion

The adhesive pads are applied by a robot. The machine is reminiscent of a price labeler from the supermarket.

The employees in the paint department will also be grateful, because until now, every single hole on every body had to be sealed by hand with a plastic plug. According to Porsche, the amount of force required can be imagined as pressing a weight of seven kilograms with just your thumb. Another simplification of the processes: there is only one adhesive pad for the four available hole sizes, which is sufficient to cover them all. The Tesa parts are only one millimeter thick and come to 33 millimeters in diameter. Even if the hole is overlapped by just two millimeters, the adhesive effect is supposed to be permanently sufficient. Sounds like you’d better not press such a “Bäbberle,” as the Swabian would say, onto your own skin.


Incidentally, the new Taycan base model with rear-wheel drive recently became Porsche’s entry into electromobility. For more information and impressions, take a look at our photo show.


At a Techday 2018, the idea of replacing plugs with adhesives was born. In Porsche’s paint department, this has now become everyday work. It may sound strange to say that a Taycan like this is glued with Tesa, but according to Porsche, the small pads certainly seem up to the task.

Leave a Reply

Your email address will not be published. Required fields are marked *