Tesla Is on the Verge of Another Manufacturing Breakthrough

Tesla is set to increase their manufacturing lead

Tesla

Tesla is nearing a pivotal moment in its journey and the automotive industry. According to a detailed report by Reuters, the company is on the brink of a groundbreaking manufacturing evolution, set to revolutionize the production of its next vehicle and set a new standard for the future of vehicle creation.

Drawing on insider knowledge from five anonymous sources, the report sheds light on Tesla's innovative gigacasting process, poised to redefine the manufacturing landscape and help Elon Musk realize his ambition of halving production costs. A decision on this significant shift could be made later this month.

A Single-Frame Approach

The key to this disruption lies in Tesla's commitment to unboxed manufacturing - a strategy introduced by Musk in March. At its core, this strategy focuses on the die-casting of nearly the entire complex underbody of an EV in one singular piece, reducing the traditional assembly of around 400 parts in a conventional car to a singular entity.

Tesla has used technology in several areas of its operation, notably a recent single-piece front casting for the Model Y that resulted in 169 fewer pieces and 1,600 fewer welds.

Tesla's unboxed strategy could roll out soon, drastically cutting production time and costs. According to Reuters, Tesla's forthcoming $25,000 car presents the perfect canvas for this one-piece casting revolution, bearing a simpler underbody resembling "a battery tray with small wings."

The Material Difference

To bring this vision to life, Tesla's global team, based across the UK, Germany, Japan, and the US, has leveraged 3D printing and industrial sand. Utilizing binder jets, which construct molds layer by layer through the deposition of a liquid binding agent on a sand layer, the team can quickly create and adapt prototype molds. This process significantly cuts the traditional costs associated with metal prototype creation, paving the way for rapid iteration at just 3% of the usual expenditure.

Beyond molding, Tesla has also been developing special alloys to overcome challenges in crashworthiness and other attributes associated with the different behaviors of these materials in sand and metal molds. These alloys, aligned with a fine-tuned molten alloy cooling process and post-production heat treatments, have potentially set the stage for a large-scale manufacturing revolution.

Tesla is deliberating on the exact nature of the die-casting process - whether embracing high-pressure techniques for speed or opt for slow alloy injection to ensure quality and versatility. The choice between these methods implicates not only the complexity of the car frame but also dictates the need for potentially more significant factory buildings and Giga Presses boasting a staggering clamping power of over 16,000 tons.

Strategic Shift to Giga Texas

This aligns with recent insights from Walter Isaacson's biography of Elon Musk, illustrating a strategic shift in Tesla's operations. Initially slated for Mexico, the production hub for the next-generation EV platform will now reside in Giga Texas. This will allow Musk to keep a closer eye on the development, design engineers and the manufacturing hub to facilitate immediate feedback and streamline processes. The book also said that Giga Mexico would still play a significant role, but now it seems it would be where the new technology would be housed after being perfected in Texas.

As the clock ticks down to Tesla's final decision, one thing remains clear: a potential transformative moment in EV manufacturing is on the horizon, promising a future where Tesla's EVs are more affordable, attainable, and revolutionary than ever before. It is not just a step but a gigantic leap toward the future of automotive manufacturing that only a visionary like Musk could envision and endeavor to achieve.

Tesla Confirms Update Issue for FSD V13.2.2; Fix Coming

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A member of Tesla’s AI development team, Kalena Brown, took to X to mention that an update is on its way for AI 4 vehicles on older FSD V13.2 builds.

It seems that Tesla has caught an issue that has been preventing vehicles from safely updating from FSD V13.2.2 to newer builds such as FSD V13.2.4 or V13.2.6.

The Bug

Tesla usually catches these issues early in testing, but sometimes, they make their way out into the wild, necessitating a stop to a rollout. In this case, the rollout was likely halted to prevent this issue from spreading to other vehicles.

There have been a lot of comments on social media that users haven’t seen an update since late December or early January. While that’s not completely abnormal, this update, version 2024.45.25.5 includes an issue that prevents it from being updated.

Please be patient! Found an issue specific to that update path, but fix is coming soon

Many folks on older builds also waiting and we're working hard to get everyone covered 🙂

— Kalena Brown (@KalenaKBrown) February 7, 2025

The Fix

Brown says that Tesla is aware of the issue and is working hard to get a build with the fix released soon. It may be a couple of weeks before it’s ready, but you can expect Tesla to roll this one out slowly to make sure the issue is addressed.

The issue appears to be specific to FSD V13.2.2, so anyone on another update should not be affected. Keep an eye out on our feeds - and we’ll let you know once the update is released.

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Tesla to Introduce New Paint Options for New Model Y in North America

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Tesla introduced the Refreshed Model Y in North America with just four colors - Stealth Grey, Pearl White Multi-Coat, Ultra Red, and Quicksilver. While those are likely some of the most popular colors - many have been asking - what about new color options?

Actually - what even happened to Deep Blue Metallic - one of the most popular Tesla color choices? Well, thanks to an interview between Tesla Owners Club Silicone Valley and some of Tesla’s vehicle engineers, we now have more details.

New Paint Options

More paint options are around the corner for the new Model Y, but they won’t be available just yet. In fact, they’ll likely be available once the Launch-Series wraps up - as those vehicles are shipping in May.

One of Tesla’s latest colors, Glacier Blue, debuted in the Asia-Pacific market, but for now, North America remains limited to a select set of options. Deep Blue Metallic continues to be one of Tesla’s most popular choices, and black is also a favorite, though it is currently unavailable for new Model Y orders.

In a recent interview, Tesla’s engineering team confirmed that new colors are already being developed. However, the key factor delaying their availability is production ramp-up. Just as scaling vehicle production takes time, expanding paint production capacity is a gradual process. Tesla is prioritizing a smooth production ramp before adding more color options to the lineup.

New Color Hints

The engineering team also mentioned that if you “put two and two together” while browsing the website, it will be pretty evident which colors are coming. This suggests that the new colors will not be completely new but will be colors that are available on other models or in other regions. The primary candidates are Glacier Blue, which is available in Asia, and Deep Blue Metallic and Black, which are available for the now, last-gen Model Y.

It seems like once production ramps up, Tesla will be ready to introduce some new paint options. Maybe they’ll introduce them alongside the expected refreshed Model Y Performance? If you’re in the market for a paint option that isn’t available in North America just yet - it could be best just to wait a few months.

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