The most crucial part of a Tesla is the battery. One advantage Tesla has over the competition is their excellent battery regulation. Batteries in a Tesla last longer when compared to the competition due to Tesla’s excellent battery monitoring.
There are four major contributors that lead to lithium-ion battery degradation, which we would like to minimize. The first two we don’t have much control over, which are the age of the battery and the number of charge cycles (the number of times the battery has been charged and discharged).
However, the last two, we do have control over. Lithium-ion batteries don’t like to remain in a very high, or very low state of charge. That doesn’t mean we should never charge to 100% or use it down to 5%, but it’d be wise to minimize those occurrences. The last thing is the temperature of the battery. For the most part, Tesla handles this automatically. The batteries are heated and cooled to stay in a healthy temperature range without you ever knowing, even if the car is off. The car will also limit power when driving if necessary.
If you’re going on vacation and leaving your car at home or at the airport here are some things to consider.
If you can leave your car plugged in while at home or the airport
If you can leave your car charging, then absolutely do this, this will make things much easier and let the car control everything itself without you ever having to worry about it
Lithium-ion batteries are best stored at around 50% of charge, so set your charge level in the Tesla app or the car to 50%. The car will automatically use some energy when needed to cool or heat the battery, and it’ll get this power directly from the power source instead of Tesla’s batteries.
Keep the car in a garage or under a cover if possible, this will help keep your car away from extreme elements such as snow, ice and heat. In general, this is just good practice.
If you can not leave your car plugged in at home or the airport
If you can not leave your car plugged in while going on vacation there are several more things we need to account for to prevent any possible issues longer term.
If the weather is extreme, whether it’s extremely cold or hot and you can not park in an isolated area and are going away for more than two weeks, then you may want to consider a different mode of transportation. If the car battery is drained completely, it could lead to battery damage since the car can no longer keep the batteries at an ideal temperature and it’ll no longer be able to protect itself from harsh weather.
If you're going to be gone more than a few days, try to have your car charged to 90% as it will consume some energy as it's parked. If you're only leaving for a day or two, then a 70 - 80% charge should be more than fine.
Since your car will be unplugged and unable to charge, you can help preserve the battery by turning off Sentry Mode if it won’t be needed as this consumes quite a bit of energy.
You will also want to turn off Stand By Mode in the Autopilot menu. Standy By Mode keeps your car's computer on so that you have instant access to features such as Summon. However, it does use additional energy.
To further preserve the car's battery, you can turn off Cabin overheat protection, which is used to keep the cabin from overheating. The car attempts to keep the cabin below 105°F.
Keep the car away from harsh weather, if it's winter then keeping it in a parking garage and away from wind will help. If it's the dead of summer, then also try to keep it under a covered area in the shade if possible.
If you’d like to check in on your car, it will need to have a good cellular connection.
Before leaving, confirm that the car has a good connection so that you can check on the battery level if needed. However, do not open up the Tesla app often, as doing so will wake up the car and keep it awake for about 15 minutes, consuming more energy. Only check on the car if you absolutely need to.
Keep in mind the amount of charge you’ll need in your car when heading back home or reaching your first charging destination. If you’re leaving your car plugged in, then you can expect the car to remain at the same charge percentage if there are no power outages. However, if the car is not plugged in, it may have a significantly less charge when you return.
As you can tell, it will be much easier and safer if you’re able to leave your car plugged in while going on vacation, especially if it’s for an extended period of time.
If you plan to store your Tesla for longer periods of time, you should find a place to keep your Tesla plugged in and follow the “if you can leave your car plugged in” tips above.
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Tesla’s Cybertruck has officially earned a 5-Star Safety Rating from the NHTSA—an impressive achievement given the vehicle’s design. The achievement demonstrates Tesla’s engineering prowess. As one engineer points out, it wasn’t an easy feat.
Interestingly, the NHTSA only recently disclosed the results, despite the crash tests being completed a while ago. According to Lars Moravy, Tesla’s VP of Vehicle Engineering, the team had been aware of the 5-star rating for quite some time. While the reason for the delay remains unclear, now that the results are public, Tesla’s engineers can finally share how they achieved the rating.
Crumple Zones
Wes Morril, the Cybertruck’s Lead Engineer, wrote about the crash test video on X recently, addressing the claims that the Cybertruck doesn’t have a crumple zone. He also posted a side-by-side video (below) of the engineering analysis and the crash test itself.
Engineered Crash Safety
There’s a lot of engineering precision at play when a Cybertruck is involved in a crash. Unlike traditional crash structures that rely on crash cans and collapse points, the Cybertruck’s front gigacasting is designed to absorb and redirect impact forces in a highly controlled manner.
It all starts with the bumper beam, which crushes within the first few milliseconds of a high-speed impact. At the same time, the vehicle’s sensors rapidly analyze the crash dynamics and determine the optimal deployment of safety restraints, including airbags and seat belt pre-tensioners. These split-second actions are crucial in keeping occupants safe.
As the crash progresses, the vehicle’s structure deforms in a carefully engineered sequence. The drive unit cradle bends, directing the solid drive unit downward and out of the way, allowing the gigacasting to begin absorbing impact forces.
The casting crushes cell by cell, methodically dissipating energy in a controlled manner. This gradual deceleration reduces the g-forces transferred to occupants, making the crash much less severe. As the gigacast begins crushing, the safety restraints are deployed.
As Wes points out in his post - you can see how accurate the virtual analysis and modeling were. The video shows the simulated crash side by side with the real-life crash test and they’re almost identical. All that virtual testing helps provide feedback into the loop to design a better and safer system - one that is uniquely different than any other vehicle on the road.
All the armchair experts claimed the Cybertruck has no crumple zone and I get it, the proportions seem impossible. It was a tough one and there is a lot of engineering that went into it. Let me break it down for you:
Tesla has pioneered the use of single-piece castings for the front and rear sections of their vehicles, thanks to its innovative Gigapress process. Many automakers are now following suit, as this approach allows the crash structure to be integrated directly into the casting.
This makes the castings not only safer but also easier to manufacture in a single step, reducing costs and improving repairability. For example, replacing the entire rear frame of a Cybertruck is estimated to cost under $10,000 USD, with most of the expense coming from labor, according to estimates shared on X after high-speed rear collisions.
These insights come from Sandy Munro’s interview (posted below) with Lars Moravy, Tesla’s VP of Vehicle Engineering, highlighting how these advancements contribute to the improvements in Tesla’s latest vehicles, including the New Model Y.
However, with the new Model Y, Tesla has decided to go a different route and eliminated the front gigacast.
No Front Casting
Tesla’s factories aren’t equipped to produce both front and rear castings for the Model Y. Only Giga Texas and Giga Berlin used structural battery packs, but these were quickly phased out due to the underwhelming performance of the first-generation 4680 battery.
Tesla has gone back to building a common body across the globe, increasing part interchangeability and reducing supply chain complexity across the four factories that produce the Model Y. They’ve instead improved and reduced the number of unique parts up front to help simplify assembly and repair.
There is still potential for Tesla to switch back to using a front and rear casting - especially with their innovative unboxed assembly method. However, that will also require Tesla to begin using a structural battery pack again, which could potentially happen in the future with new battery technology.
Rear Casting Improvements
The rear casting has been completely redesigned, shedding 7 kg (15.4 lbs) and cutting machining time in half. Originally weighing around 67 kg (147 lbs), the new casting is now approximately 60 kg (132 lbs).
This 15% weight reduction improves both vehicle dynamics and range while also increasing the rear structure’s stiffness, reducing body flex during maneuvers.
Tesla leveraged its in-house fluid dynamics software to optimize the design, resulting in castings that resemble organic structures in some areas and flowing river patterns in others. Additionally, manufacturing efficiency has dramatically improved—the casting process, which originally took 180 seconds per part, has been reduced to just 75 seconds, a nearly 60% time reduction per unit.
Advancements in die-casting machines and cooling systems have allowed @Tesla to dramatically reduce cycle times and improve dimensional stability. pic.twitter.com/WB5ji67rvV
Tesla’s new casting method incorporates conformal cooling, which cools the die directly within the gigapress. Tesla has been refining the die-casting machines and collaborating with manufacturers to improve the gigapress process.
In 2023, Tesla patented a thermal control unit for the casting process. This system uses real-time temperature analysis and precise mixing of metal streams to optimize casting quality. SETI Park, which covers Tesla’s manufacturing patents on X, offers a great series for those interested in learning more.
The new system allows Tesla to control the flow of cooling liquid, precisely directing water to different parts of the die, cooling them at varying rates. This enables faster material flow and quicker cooling, improving both dimensional stability and the speed of removing the part from the press for the next stage.
With these new process improvements, Tesla now rolls out a new Model Y at Giga Berlin, Giga Texas, and Fremont every 43 seconds—an astounding achievement in auto manufacturing. Meanwhile, Giga Shanghai operates two Model Y lines, delivering a completed vehicle every 35 seconds.
![A Look at the Tesla Cybertruck’s Crumple Zones [VIDEO]](https://www.notateslaapp.com/img/containers/article_images/cybertruck/cybertruck-crash-test.webp/e43ef2433bd6e44ae8db63421604a4fb/cybertruck-crash-test.jpg)
