Ford will add a Tesla (NACS) port to its future EVs
Tesla
In a move that attests to Elon Musk's words on fostering industry collaboration over competition, Tesla and Ford have announced a partnership to enable the latter's electric vehicles access to Tesla’s extensive Supercharger network.
Ford's Green Light to Tesla's Charging Technology
Contrary to earlier speculations that Tesla's move to open its proprietary charging connector might be a futile attempt at standardization, Ford has embraced the North American Charging Standard (NACS) - Tesla's charging system. With this, Tesla’s charging plug design, known for some advantages over the current CCS standard, might start gaining traction across the North American EV sector.
This agreement with Tesla allows Ford EV owners to enjoy the expansive Supercharger network through an adapter named “Magic Dock,” which is being deployed at Superchargers. Starting early next year, Ford EV customers will have the luxury of charging at more than 22,000 stations — 12,000+ Tesla Superchargers and 10,000+ DC fast-chargers already part of the BlueOval Charge Network.
Ford EVs to Directly Integrate Tesla's Connector
Signaling a significant step in EV charging standards, Ford plans to incorporate Tesla’s NACS connector into its future electric vehicles starting in 2025. This will allow Ford EVs to access Tesla Superchargers without needing an adapter directly. More importantly, it could allow Ford vehicles to charge at more Superchargers, which do not have the Magic Dock adapter. Jim Farley, Ford's president and CEO, expressed enthusiasm about this breakthrough agreement, hailing it as vital for Ford's growth as an EV brand.
The impressive reliability of Tesla’s Supercharger network was a major factor in Ford's decision to facilitate the use of the network for its EV owners. Tesla's Superchargers have a near-perfect uptime rate of 99.95%, offering a dependable solution to the charging needs of Ford's EV customers.
Evolution of the BlueOval Charge Network
Ford's existing charging network, the BlueOval Charge Network, already boasts over 84,000 chargers. The addition of Tesla Superchargers will bolster its infrastructure, significantly reducing range anxiety for Ford customers. In tandem, Ford plans to add approximately 1,800 public-facing fast chargers to the BlueOval Charge Network by early 2024.
Elon Musk’s Supportive Approach to Industry Collaboration
This partnership exemplifies Musk's commitment to industry collaboration over annihilating competition. Following a precedent set by Henry Ford's assembly line revolution, Tesla's continuous advancements in EV technology and strategic price reductions have led to questions about the future of other automakers in the EV market. However, unlike Ford's competitive approach a century ago, Tesla's actions aim to accelerate the advent of sustainable transport by enhancing access and efficiency of charging for all EVs.
This partnership is a significant milestone in the EV industry, setting a course toward a collaborative and innovative future. While it brings a superior charging experience for customers, it also propels the world’s transition to sustainable energy, emphasizing the shared goal of all players in the EV sector.
Subscribe
Subscribe to our newsletter to stay up to date on the latest Tesla news, upcoming features and software updates.
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)
