Thanks for the writeup, Francis. Great detail.
Fogging: as Lloyd notes, A/C is critical to defrost. When the window fogs, I typically hit the "front defrost" button and it usually goes away almost right away. When it doesn't, I look at the climate settings, and the A/C is not on - which I find curious, isn't that typically an important part of a defrost setting? I have not checked to see if A/C is on when the defroster works; but I do know it's never on when the defroster fails. So I turn A/C on, and the fog goes away. I see patpeterson has had trouble even with A/C on; but to anybody else having trouble, make sure you try A/C - it makes a huge difference in my car.
A/C is definitely an important part of the defrost setting, because automotive A/C is also a de-humidifier. If the air inside the Model S becomes humid, and the temperature of the glass is low relative to the inside air temperature, the air near the glass will cool and condensation will form as water vapor turns to liquid. Therefore, to remove condensation effectively, the windshield must be slightly heated, to keep or turn the water there to gaseous state, AND the water in gaseous state must be removed from the cabin.
Three steps to effective defrosting of any car glass:
(1)
Air Conditioner turn ON
(2)
Blower fans directed to Windshield/Side Windows
(3)
Crank the Heat
A,B,C hopefully easy to remember. I came up with this years ago when I first started driving and had a scary incident with fogging windows.
On a cold day, it is always best to do the A, B, C procedure
immediately after buckling up and turning on the vehicle.
I'll bet the interior blower motor is on the passenger side, and the way they're routed the ducts, the passenger side gets more blower power than the driver's side (longer duct run). If so, it's probably not an easy fix short of new HVAC duct-work.
The grill along the edge of the windshield looks more like speaker grill, and from casual observation, it doesn't look like it would direct the airflow to the windshield that well.
A re-worked grill with fins to direct the air flow onto the windshield might be more effective. I agree that a new HVAC duct design might be necessary to direct more air to the Driver's side windshield and side window.
For
emergencies - clean terry towel, microfiber cloth, or worn out t-shirt will quickly remove condensation and plastic film from off-gassing of interior plastics.