Tesla talks about it's next-gen vehicles at Investor Day
Tesla (Edited by Not a Tesla App)
Tesla's Investor Day peaked at around 145 thousand viewers on YouTube as the company's vehicle designer and engineering leaders gave their presentation. Viewers were hoping for a new product announcement. However, the view count quickly dropped, and the nasty comments increased as the leaders wrapped up their portion of the show.
After a presentation on reducing costs and finding efficiencies, chief designer Franz von Holzhausen said, "I think our track record proves that we can deliver the best cars, and we deliver the best cars despite, because of, these constraints. I'd love to show you what I mean and unveil the next-gen car. But you are going to have to trust me on that until a later date."
Then, perhaps sensing the disappointment as the air left the room, he added, "I promise we will always be delivering exciting, compelling, and desirable vehicles as we always have."
Not One, But Multiple New Teslas
While we have to wait for the next platform launch, we did get some more details. Lars Moravy, the Vice President of Vehicle Engineering, said, "The next-generation platform is not one vehicle; it is multiple, and it's in a segment that we really try to focus on affordability and desirability."
He added, "Our next-generation platform is more than one segment, and really we are thinking of all the segments that are available that we haven't captured and where the market would be."
So while we have been trying to determine if the next vehicle will be an affordable car or a "highly configurable" van, both guesses are correct. Tesla has major plans for the affordable car, often called the Model 2. A slide detailing what Tesla's global fleet would look like to achieve a sustainably powered earth, the covered-up 'Model 2', accounts for nearly all of the other cars models combined. The Master Plan suggests there are 700 million cars in the Model 2's category and 740 million of the rest.
Franz Talking About the Next-Gen Platform
Watch Franz von Holzhausen talk about Tesla's next-gen platform. The video below starts at the beginning of the segment:
Easier Said Than Done
It's not so easy to create a vehicle that will change the world. Musk stated, "The issue is how do we build the cars. The hard part is how do we build the cars. I can't emphasize that enough. The hard part is building the cars and the entire supply chain that goes with the cars. This is a logistics challenge of extraordinary difficulty."
It's not just building the physical car but also where to make it, according to Zach Kirkhorn, Tesla's CFO. "As we have been thinking about our next-generation platform, we have been thinking about the volume that we aspire to build against that, how many individual factories do we need to build, and what is the fastest possible way to expand that footprint around the world."
Infinite Demand
So, while investors may go away disappointed in the short term, long-term, there is plenty of positives. Musk was asked about the risk of the new affordable car taking away the demand for other Teslas. His answer was very pointed, "demand for our existing vehicles in terms of the desire to own them might as well be infinite. It's indistinguishable from infinite at this point. Affordability is what matters, as you get the car more affordable, demand will go crazy - basically."
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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)
