Rivian is the latest manufacturer to adopt Tesla's connector
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Adding to the recent trend of manufacturers endorsing Tesla's charging standard, Rivian has adopted the North American Charging Standard (NACS). This move, expected to take effect in spring 2024 with Rivian users utilizing adapters, is a significant step towards standardizing EV charging infrastructure. Starting in 2025, Rivian vehicles will come equipped with Tesla-style charging ports as a standard feature.
Rivian Joins Ford, GM in Embracing Tesla's Charging Standard
In what seems to be an emerging industry pattern, Rivian follows in the footsteps of auto giants Ford and General Motors, who have recently committed to Tesla's charging standard. Rivian's CEO, RJ Scaringe, voiced his preference for the compactness of Tesla's connector and the opportunity to utilize the existing charging infrastructure that Tesla has painstakingly built.
Rivian, whose share prices have struggled until this key announcement, seeks to capitalize on the customer convenience and operational efficiency offered by Tesla's extensive Supercharger network. This move also implies an anticipated rise in Rivian's stock value, as was observed with Ford and GM after their similar announcements.
Tesla's Supercharger Network Opens Up to More EVs
With Rivian's adoption of the NACS, Rivian customers can look forward to accessing Tesla's 12,000-strong Supercharger network across the US and Canada. Existing Rivian vehicle owners are also set to benefit, with Tesla-designed adapters becoming available in spring 2024.
Tesla’s Charging Leadership - Who's Next?
The wave of adoption surrounding Tesla's NACS seems far from over, with Rivian's decision adding momentum to the trend. Speculation is rife over who will be the next EV manufacturer to join this growing alliance. Notably, Hyundai has indicated an interest in joining this cohort, which could further strengthen the case for NACS and Tesla's leadership in the EV charging landscape.
Tesla's recent traction in setting the industry charging standard reflects the increasingly recognized benefits of the NACS. Several major industry players, including BTC Power and EV charging providers like ABB E-mobility North America, Tritium DCFC, and EVgo, are rushing to add NACS plugs to their charging stations, heralding a potential shift towards widespread standardization.
A Rising Tide Lifts All Boats
The acceptance of the NACS by a growing number of automakers is not just a victory for Tesla but for the entire EV industry. A universal charging standard simplifies the charging experience for all EV drivers, further encouraging the transition from internal combustion engines to electric power. Rivian's commitment to the NACS illustrates the company's acknowledgment of this fact, despite its previous endeavours to build its charging network.
The push towards a standardized charging infrastructure could catalyze wider EV adoption by mitigating the charging-related anxieties of potential EV buyers. As more and more car manufacturers follow suit in recognizing Tesla's NACS, the overall landscape of the EV industry is set to change drastically.
This trend may also play a pivotal role in promoting the collaboration and unity needed to achieve carbon neutrality goals worldwide. With Rivian joining the bandwagon and other major players likely to follow, Tesla's NACS continues to set the course for the future of EV charging, one plug at a time.
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.
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