Exclusive: Tesla's Model 3, Project Highland Exposed: What’s Changing

By Kevin Armstrong
Tesla's Model 3 is going to go through some of its biggest changes this year
Tesla's Model 3 is going to go through some of its biggest changes this year
Tesla

Tesla has been working on a revamp of one of its most popular vehicles, the Model 3. The project is codenamed Project Highland and the vehicle will see the most profound changes since it launched in 2017.

Despite Tesla keeping the car under wraps for months, we now have early information on the major changes coming to the best-selling electric vehicle of all time. Thanks to a trusted insider, we can confirm and provide more information about Tesla's plans for the car. Inside and out, the Highland will change.

Redesigned Headlights

Caped Model 3s have been spotted with the front bumper, rear end and dash covered. However, more recently the incognito Model 3 also had its headlights covered. The headlight openings that were clear before were now covered in what appeared to be duct tape. Turns out there is a good reason for this. The Model 3 revamp will include redesigned headlights. The new headlights will be a different shape than they are today. Tesla has been providing some models with matrix headlights, but they have yet to be enabled through software yet. Tesla will continue to offer matrix headlights through this redesign, although it's not clear whether they'll be enabled at launch either.

The revamped Model 3 is known internally as Project Highland
The revamped Model 3 is known internally as Project Highland
The Kilowatts/Twitter

Bumper Camera

A new shape of headlights also means a new front bumper. There has been a lot of speculation that the front of the car is changing after recent images show a smoother front end. Tesla is always looking for more aerodynamics to improve the drag coefficient. However, there's another good reason for redesigning a new front bumper. The front bumper will now house a single camera in the center area of the lower-vent area of the bumper.

The location of the new camera will be very similar to the one shown off on the Cybertruck at Tesla's Investor Day.

The Cybertruck will have a camera in the center of the front bumper
The Cybertruck will have a camera in the center of the front bumper
Sofiaan/Twitter

Since the company removed USS, people have been wondering how the car will detect objects in what's considered a camera blind spot directly in front of the vehicle. Now we know.

Rear Bumper

The rear bumper of the vehicle is also being redesigned, although it's not clear why. We don't expect the rear camera to change position and there won't be additional cameras in the rear of the vehicle. The new rear bumper could just be to 'refresh' the car or may have cost-saving measures.

Mirrors

Updated mirrors are also joining the party. We're told that they will receive a very minor 'refresh' and will look very similar to the way they do today. It's not clear whether Tesla is changing them to match other areas of the vehicle better or to streamline manufacturing, but we've been told to expect a minor change.

Additional Cameras

Tesla recently launched hardware 4.0 on Model S and Model X cars, although many were surprised to learn that the new vehicles feature the same number of cameras as HW 3 vehicles, when hardware 4 allows for more cameras. This is where Project Highland comes in.

We can now say that more cameras will indeed be used in Project Highland. There will be three new cameras in all, one in the center of the front bumper as we discussed earlier, and two more on the sides of the vehicle.

The fender camera housing will now contain two cameras each. One will face backward as it does now, while the other will point in the other direction. It's not clear how the new camera will be oriented, but we speculate that they will be aimed off to the side to give the car a better view at certain intersections.

Some road junctions have objects such as buildings or bushes that can make it difficult for the vehicle to see with its B-pillar cameras. This often causes the vehicle to creep forward in order to gain enough visibility to proceed. Creeping too far forward sometimes causes the vehicle to be in a poor situation, where it has entered the path of other vehicles. These new cameras are likely aimed at solving this problem.

As previously reported, the repeater camera housing on the front fenders appears to be changing. It now appears to include a line that goes further back than the original. This could be part of the new design.

Project Highland will ship with Tesla's latest supercomputer, Hardware 4. The cameras themselves are expected to be the same cameras featured on HW4 Model S and Model X vehicles. They're estimated to be 5-megapixel cameras with an anti-glare coating. These cameras are significantly more advanced than the current 1.2-megapixel cameras in current HW 3 vehicles.

With the new front bumper cameras and the two additional side cameras, Tesla may now have everything it needs in order to provide a real birds-eye view that is often seen in many vehicles.

Sensors

In order to cut costs, Tesla is removing the vehicle's temperature sensor that is used to detect the temperature outside of the vehicle. Instead of using a temperature sensor, the vehicle will determine the exterior temperature based on its GPS location and weather data. This could lead to more accurate temperatures being displayed, as wind or other environmental factors can sometimes cause inaccuracies. However, owners will lose the ability to view the temperature in their immediate location, such as their garage.

Tesla is also making improvements to its GPS module which is expected to provide a more accurate location. In August 2022, Tesla applied for a patent on a multi-band Global Navigation Satellite System (GNSS) antenna. Various types of satellites and networks can be used to identify an object's location. GPS is just one of those networks. This new system allows Tesla to use other networks, besides GPS, in order to identify the vehicle's location. This could lead to faster location detection or higher precision.

Interior

Inside the vehicle, there will be some changes as well. However, don't expect a major refresh as we saw with the 2021 Model S, but it will still be noticeable. The wood trim is being removed and replaced with a fabric finish, possibly Alcantara fabric that Tesla already uses in the Model S and X.

The vehicle's dash will also receive a facelift, but we weren't given any details on what's changing with it. Again, this could be a way to simplify the manufacturing process instead of offering something new and improved.

There may be other interior changes, but these are expected to be the two bigger differences. We've been told that this refresh will be 'minor' and focuses on cost-cutting, however, it appears that Tesla is taking the time to upgrade the vehicle to its newest hardware and introduce new cameras, which will certainly be a highlight of the vehicle.

The Model Y project, codenamed Juniper is already underway as well, although it's expected to arrive after the Model 3 revamp. We expect the Model Y to undergo many of the same changes that we've outlined here.

Release Date

Overall, the Model 3 Highland's updates show that Tesla is always looking for ways to improve its vehicles and stay ahead of the competition. As is the nature of these things, some items could be subject to change. With these changes, the Model 3 will continue its success as one of the most popular electric vehicles on the market. Production for the vehicle is expected to start in the third quarter.

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Tesla Eliminates Front Casting on New Model Y; Improves Rear Casting

By Not a Tesla App Staff
Not a Tesla App

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.

New Casting Methods

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.

Tesla’s Hands-Free Trunk and Frunk – Supported Models, Phones & How to Set Them Up

By Karan Singh
Not a Tesla App

Having the ability to open your trunk hands-free can be incredibly useful when your hands are full, especially in a busy parking lot.

Tesla vehicles now support opening the vehicle’s trunk or frunk completely hands-free — no foot waving required.

What is Hands-Free Frunk and Trunk?

Tesla implemented its hands-free feature by leveraging your phone’s position in relation to the vehicle. When you stand still behind your vehicle, the trunk will automagically open for you.

While this functionality isn’t available on every vehicle, it’s available on every vehicle Tesla manufactures today, including the new Model Y, the Cybertruck and other recent models.

With a compatible device and a supported vehicle, you can now open your Tesla’s trunk hands-free.

How It Works

Tesla’s hands-free feature requires the use of ultrawide-band (UWB) in the vehicle and on your phone. Apple and Samsung have supported ultra-wideband for a number of years and most flagship Android devices also support the low-energy feature.

Ultra-wideband allows another device to precisely detect its relative location. In this case, the vehicle is tracking where the driver’s phone is in relation to the vehicle. Since the vehicle is able to more precisely track the phone’s location, ultra-wideband also improves Tesla’s phone key feature.

Since the vehicle depends on your phone, you’ll need to have your phone on you in order to activate the hands-free feature. Simply stand within 2.5 to 3 feet from the front or rear of your vehicle for the frunk or trunk to open. You’ll then hear a couple of chimes. If you continue to stand still, then your frunk or trunk will open automatically.

The chimes serve as a warning that the trunk will open if you don’t move, which helps reduce accidental openings.

Hands-Free Trunk in Action

The video below shows how Tesla’s hands-free trunk feature works.

Supported Models

Since Tesla uses ultra-wideband to power the hands-free feature, only vehicles with the needed hardware are supported. The list of supported vehicles includes:

  • 2021 Model S and later

  • 2021 Model X and later

  • 2024 Model 3 (Highland) and later

  • 2026 Model Y (Juniper) and later

  • All Cybertrucks

Supported Phones

Your phone will also need to support UWB. Luckily, most manufacturers have included UWB in their devices for several years.

Apple: All Apple devices since the iPhone 11 have included UWB, except for the iPhone SE (2nd and 3rd generation). The iPhone 16e also has UWB.

Android: Most Android phones - especially flagship devices - already support and use UWB for other uses, but it’s not available on all phones. If you have a Google Pixel 6 or higher, Samsung Fold 2 or higher, Samsung S21+, or other recent Android phone, then your phone already supports ultra wideband.

Which Models Support Hands-Free Frunk

Unfortunately, not every supported model supports the hands-free frunk and trunk feature. The hands-free frunk feature is only supported on the Model S, Model X, and the Cybertruck. In addition, the Cyebrtruck is the only vehicle with a powered frunk, so while the Model S and Model X will unlock the frunk for you, you’ll still need to lift it and close it manually. The Cybertruck will open the frunk for you, much like the trunk on another Tesla.

Which Models Support Hands-Free Trunk

While most supported Tesla vehicles can use the hands-free trunk, it excludes the Cybertruck, which doesn’t have a powered trunk.

Enable Hands-Free Trunk / Frunk

If you plan to use your vehicle’s hands-free trunk feature, you’ll need to enable it in settings, as it’s off by default. Simply open Controls by tapping the vehicle icon in the bottom left corner, then navigate to the Locks section.

Within the Hands-Free section, you’ll find a few options, depending on your model. You’ll be able to choose whether to enable the hands-free frunk or trunk and whether you’d like to disable the feature at home.

Preventing Accidental Opening - Exclude Home

Although the hands-free feature requires you to stay still in front or behind your vehicle for a couple of seconds, it can still be triggered accidentally if you’re working around your garage. To prevent accidental opening of the frunk or trunk, Tesla allows you to disable the feature while your vehicle is parked at home.

Tesla determines your home location by the address that’s set in your vehicle. However, it also adds a buffer, meaning that your hands-free trunk feature will also not work in your driveway or at your neighbor’s home. The exclude home feature is located in the same spot as other hands-free trunk features, Controls > Locks > Hands-Free > Exclude Home.

If you have a recent Tesla that’s supported, go ahead and give the feature a try.

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