One possible issue I have heard about regarding paint problems in particular is that California State and Bay Area local authorities have particularly tight limits on VOCs in terms of lbs per gallon of paint, and in terms of total annual lbs of VOC emissions which the Tesla paint shops are allowed to emit.

I believe the Federal standard is 5.0lbs/gallon but CA limits that further to 3.5lbs/gallon. Apparently it’s pretty hard to make decent hard coat paint with that little VOC emissions.

The BAAQMD (Bay Area Air Quality Management District) also permits Tesla paint shops for a maximum total annual VOC emission level. This level could be low enough that either the paint shop becomes a production bottleneck, or they have to find ways to use less paint per vehicle.

It can’t be easy to manufacture cars in the regulatory environment that is the Bay Area, and many of these regs have tightened significantly since GM & Toyota closed NUMMI in 2010. CARB VOC limits, and local air quality district regulations in particular.

I’m sure this is an issue that all manufacturers are facing to some degree, but it’s interesting how the location of the final assembly plants can have a big impact on the regulations and therefore the finishing processes that can be used.

EDIT: That’s not to say the limits should not exist, or Tesla should be granted a waiver, etc.