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.
Subscribe
Subscribe to our newsletter to stay up to date on the latest Tesla news, upcoming features and software updates.
Last week, Mark Ruber, an engineering YouTuber best known for his glitter bombs, released a video where he tested Tesla's Autopilot against various conditions - including the iconic ACME painted wall.
During this test, many people noted that Mark was using Autopilot rather than FSD, even though his video was titled “Can you Fool a Self-Driving Car?”. The Tesla on Autopilot went up against a vehicle equipped with Luminar’s LIDAR rig, running some sort of basic autonomy or safety software.
New Video Tests FSD
Many people were disappointed with Mark’s video and his testing methods, so several creators got to work to actually test out Tesla’s FSD.
Creator Kyle Paul over on X made a much better follow-up video, using both a HW3 Model Y as well as an AI4 Cybertruck. In a relatively unsurprising turn of events, the Cybertruck was successfully able to detect the wall, slowed down, and came to a stop. The Cybertruck was running FSD 13.2.8.
Kyle’s team did a fantastic job building the wall and testing this in a private area using FSD rather than Autopilot. On top of that - they re-tested the results several times and recorded the entire thing in and out. While Mark’s video was more for entertainment, Kyle really set out to prove what would really happen in this unlikely scenario.
Sadly, the HW3 Model Y was unable to detect the wall, and manual intervention was required in each test. While the Model Y was running FSD 12.5.4.2 rather than an FSD V12.6 build, we don’t expect this to have had a significant impact on the test - this is more of an issue with how computer vision analyzes the environment.
There are several major differences between HW3 and HW4. The first is obviously that the version that runs on AI4 is more advanced, as the hardware is capable of processing a lot more data. However, AI4 also features much higher-resolution cameras than HW3, and Tesla recently added the ability for the video feeds to be processed at full resolution on FSD V13. This could have made the difference, although it’s not entirely clear. Perhaps if HW3 gets a version of FSD V13 in the future, HW3 can be retested to see if it passes the “ACME wall” test.
Watch
Kyle’s entire video is below. It’s only 10 minutes long, so definitely give it a watch. Props to Kyle on the quick and thorough execution.
What Does This Mean for FSD?
We broke down Mark’s test - and examined all the little issues that we discovered after doing some in-depth research - you can read our analysis here.
Putting aside the issues with Mark’s testing and instead using the new results - it seems that if you were to have to fight against Wile-E-Coyote and his ACME tools with your Tesla, cartoon logic may win if you’re on an HW3 vehicle. If you’re on an AI4 vehicle, you’ll likely come to a safe stop.
Vehicle depth perception is definitely something that Tesla has been hard at work to improve - and some fairly drastic improvements came with FSD V13 that haven’t been entirely translated to FSD V12 just yet. Future versions of HW3 FSD may be able to determine that the wall is there successfully. So Kyle - if you’re reading this - don’t get rid of that wall. We’d love to see more testing in the future.
However, this entire test scenario is so out of left field… there is a good likelihood this same test would fool some human drivers as well. The most important part is that the future of autonomy will not fall for these tricks, so it's very unlikely for someone to weaponize this idea as it’d only possibly work on a small segment of vehicles.
If Wile-E-Coyote is after you, someone else may drive into the wall before your Tesla does.
Not a Tesla App
We’re not kidding, this really happened already. This isn’t a realistic scenario outside of someone trying to play an insane prank - but it’s good to know that FSD V13 is capable of dodging this.
Tesla regularly holds quarterly all-hands meetings for employees, but last night marks the first time Tesla has live-streamed the event for the public.
The meeting primarily focused on Tesla’s employees, recent achievements, and the future of Tesla. While it didn’t reveal much new information, it was interesting to see Elon Musk candidly engaging with his teams, who seem to genuinely enjoy working with him. Still, there were a few noteworthy takeaways.
As with Tesla’s Earnings Calls and other live events, we’ve put together a concise, easy-to-digest recap of everything discussed.
General Points
Work-related Injuries declined over time
Planning to expand to new markets
Cell Manufacturing
Continuing to invest in battery supply
Cheapest, lowest cost per kWh cell
The supercharger network continues to grow
Vehicle range and charging speed should match the needs of humans and their required time for breaks
![Tesla Updates Energy App in Update 2025.8.3: Adds Reset and Distance Filter [VIDEO]](https://www.notateslaapp.com/img/containers/article_images/2025/updated_energy_app.jpg/979943fb17df5ae4e9fa668b8cd61fca/updated_energy_app.jpg)
_300w.png)
![Tesla's Hidden 'Elon Mode' Unveiled: A Sneak Peek into the Future of FSD [Video]](https://www.notateslaapp.com/images/news/2022/fsd-beta-inside_300w.jpg)
