OP, I am so thankful for your post. I am 5 days in to my new Model 3 (black interior) and the off-gassing is extreme. With windows cracked while I'm at home, my whole garage now smells the same and I can even smell it in my house near the garage door.
While I'm driving, I keep at least one window cracked and never recirculate the air. Even with that, I have a sore throat within a few minutes of being in the car, and then a headache and nausea follow. After reading this whole thread, I am seriously considering whether I should take advantage of the 7 day return policy (perhaps look at some gently used Teslas?).
I live in Colorado and won't be able to drive with the windows cracked for a year. I'm not optimistic that this will fade away any time soon. Like you, I find it totally overpowering. Wondering if you've found a fix yet, or what you would do if you were in my shoes (or my seats... I think it's the seats, btw.)
Really nice to hear that I helped you with my post. I'm really sorry that you're experiencing this. I have not found a fix. My wife is driving the Model 3 and I'm not. Coincidentally I did recently ride a friend's Model 3 and it seemed hugely better (and is much newer). I don't know if it's amount of use, build quality, different supplier materials. It's probably all of the above.
Someone else posted here recently that they were also having this experience but are likely going to swap the seat material out for real leather. I would try the same myself but it's a $2000 gamble. One of us will do this and then have an answer but until then, nobody knows.
My feeling is that there is probably more of this happening in Teslas than other vehicles because (and I am just guessing here): a) They are a "break things" kind of Valley startup type company and they are likely not doing the kind of careful material science that other companies have done b) They are probably using newer or non-standard materials in an attempt, ironically, to provide a healthier, greener environment for drivers. But these materials probably have less testing behind them. c) Maybe "vegan leather" seats?
But, I digress... you asked what I would do at this point knowing what I know. So:
1. Feel free to DM me to compare details. At one point I was wondering if it might be coming from the tires (because of the strong smell in the garage, that I was keeping windows open, that the smell is reminiscent of rubber). Are you on 19" wheels or the 18" aeros? I'm happy to troubleshoot. And because we are a small minority, it's good to stick together.
2. Are you close to a service center in CO? I would tell them what's happening and see if you can come by and see if you have the same issues in other Model 3s. Maybe you can get them to agree to extend the 7-day period while you work with them to check out other cars? Not discovering that my friend's Model 3 was soooo much better than mine until now was frustrating. All this time, I was thinking that the level of off gassing was normal in my vehicle.
3. Tesla could probably resolve, or at least mitigate, this if they would stop stonewalling. They could work with owners to try to track down the offending material (be it seat or otherwise), making it safer for all customers. Make sure that service/sales relays what's happening to management and that they know that you've heard this from other owners.
The smell will definitely lessen. But, if you're as sensitive as I am to whatever the chemical is then it's also likely that it's going to be a while before you can comfortably drive it (and I'm still waiting to get my car back from my wife after 1 year). Therefore, given the choice, I would talk to sales and kind of set up to be ready to return. Knowing now that you are sensitive, I would quickly check out used Model 3s (luckily you have this option now; when I bought my Model 3 was pretty much the oldest AWD available and there was no 7-day return) to find one that seems tolerable. If you can't tolerate any of them then it's likely that yours won't be either. If that fails then there should be other manufacturer options coming along. But it's a tough time to be buying an electric car if you're sensitive because there are not a lot of used electric cars out there.
I hope this helps (and doesn't further confuse you). It's a strange place to be and the answers are definitely not clear.