Tesla's Dry Cathode 4680 Battery Cells Will Mean Cheaper, Better EVs

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During the 2024 Shareholder Meeting, Elon Musk announced that Tesla has made new innovations on the 4680 cell standard. Tesla has been working hard for several years to get a functional 4680 cell in production that either matches or beats the performance of the existing 2170 cell. The official Cybertruck account also shared an image (below) of the first 4680 dry-cathode process Cybertruck with its production crew on X.

We’re going to take a bit of a dive into the 4680, what exactly this new process and cell is, and then some of its possible advantages. So, grab your charging cable!

First prototype Cybertruck with in-house dry cathode 4680 cells – making it an all dry electrode vehicle pic.twitter.com/NzJxKQrRBp

— Cybertruck (@cybertruck) August 2, 2024

What is the Dry Process?

Dry Battery Electrode (DBE) is a different process overall from the current Wet Battery Electrode (WBE) that is common today. This dry process removes the highly toxic solvents and furnace baking processes from the equation, saving both time and space, while also being environmentally friendly.

The Dry Cathode we’re talking about specifically means that the electrode – the conducting terminal at the edges of the battery – is produced in a dry process. In the previous process, it was produced with a wet process.

Tesla’s 4680 cell suppliers – LG and Panasonic – have both been working hard to cut down on costs and ramp up their own 4680 cell production while Tesla works on their own internal improvements as well. If Tesla has found a means to easily scale the Dry Cathode method, it’ll make 4680 cells and the batteries that they are a part of - cheaper to produce.

The 4680 Cell

The 4680 cell - 46mm wide, 80mm tall

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Tesla has used the 4680 cells to make structural battery packs for the Model Y. However, these vehicles had poor charging performance and lower energy density, and they were quickly removed from sales. The sheer size of the 4680 cell made it difficult to cool, limiting its performance.

The updated 4680 cell was announced at the November 2023 Earnings Call as Cybercell, making a comeback for the Cybertruck. This new version was going to have better energy density, as well as improved charging performance.

Sandy Munro of Teardown Titan fame showed that this improved version has about a 12% energy density increase, a pretty significant improvement. You can watch his teardown of the Cybertruck below.

Tabless Design

The tabless design of the 4680 cell also has an impact on its production, and how easy it is to manufacture. Think of the tabs as the little nubs on the top of a regular small battery. The lack of tabs means that production of the cell body doesn’t have to pause to add the tabs, reducing the chance for defects with the elimination of a process, and making it faster to boot.

Removing the tab also helps in cutting down the distance that electrons have to travel to get in and out of the cell – this means less resistance, and less energy lost in the process, increasing overall vehicle efficiency.

Advantages

This new 4680 cell process has a few advantages – including an overall cost reduction of up to 50% compared to the current wet process. That’s in addition to the dry process being more environmentally friendly, which will also allow for manufacturing of the cell to scale quicker.

Tesla wants to move from the standard 2170 cell to the 4680 cell for several reasons. The biggest, by far, is cost savings. The 4680 cell is physically a bigger cell and can be used to structurally support the vehicle, meaning cost savings on both, the production of the 4680 cell and the structure of the vehicle.

Easy and Cheap

There’s more too – the 4680 cell will be easier to manufacture because of its bigger size. The 2170 cell is tall and thin, while the 4680 cell is wide and stout. In addition, its unique tab-less design is supposed to generate less resistance, improving charging speeds and cell performance.

Essentially, Tesla can fill the space taken up by 4,400 2170 cells with only 960 4680 cells. This results in a significant reduction in the material used to encase each individual cell, thereby saving space and maximizing energy density for the space the battery pack takes up.

All in all, that could mean a future price drop for the Cybertruck as well as increase the rate of production. Tesla has envisioned producing approximately 250,000 Cybertrucks per year, and they’ll need a lot of 4680 battery packs to do so.

In the future, we can see Tesla bringing the 4680 cell with all these improvements - and more - to the rest of its vehicle lineup, as they will eventually surpass the 2170 cell technology.

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Tesla Releases FSD V12.6.1 for Model 3 & Model Y

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Last night, Tesla released software update 2024.45.25.15, which includes FSD V12.6.1. This update adds support for all HW3 vehicles, including the Model 3 and Model Y. We’re excited to see the continued support for HW3 owners. 

FSD V12.6.1

V12.6.1 is now going wide, according to Ashok Elluswamy, Tesla’s VP of AI. This update is going to the Model 3 and Model Y for the first time - as only the Model S and Model X were included in FSD V12.6. 

V12.6 is a big step forward for HW3 - it includes End-to-End on Highway, Improved City Streets Behavior, and Smoother and More Accurate Tracking - all contributing towards a better, smoother, and more comfortable build of FSD. You can read our comparison between FSD V12.6 and V13.2.2 here. 

In short, FSD V12.6 performs considerably closer to V13 than V12.5.4.2 - which is a massive improvement. It performs as well as the Cybertruck version of FSD V13, which is still missing a few features when compared to other HW4 vehicles, but it’s a great sign for HW3. A lot of the improvements can be pointed to in the improvements to lane selection and decision-making - the vehicle tends to hesitate far less on V12.6, meaning the ride is a lot smoother. Many early V12.6 testers mentioned that it felt more like V13-mini than anything else.

Legacy Model S & X

We haven’t seen this update hit any legacy Model S and Model X vehicles just yet. We’re not sure whether Ashok’s statement of “generally” applies here - but it should. If you do get the update, please let us know.

Legacy Model S and Model X vehicles are still on an older FSD build and potentially won’t see another FSD update for a little while longer. While they do have the same FSD hardware as other vehicles, there are enough hardware differences that require a build specifically for these vehicles.

Release Date

FSD V12.6.1 is going out now to the redesigned Model S and X with HW3 and all Model 3 and Model Y vehicles with HW3. The initial wave went out last night, and we expect to see more later today or tomorrow. If this release ends up going “wide,” we should see much larger waves go out next week.

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Tesla Issues Physical & OTA Recall for Hardware 4 Computer

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Tesla has issued a recall for some vehicles due to issues linked to a revision of the Hardware 4 (HW4) computer that was introduced this past November. This recall affects all vehicles with the revised hardware except for the Cybertruck, as it uses a slightly modified version of the HW4 system.

Many vehicle owners have reported a complete failure of their Autopilot computer, which not only leaves the vehicle without FSD and Autopilot but also disables many of the active safety features that make a Tesla what it is.

Let’s take a look at this recall - because the recall is partially physical and partially a software recall.

HW4 Failure

Tesla has identified the failure and flagged it to the U.S. NHTSA (but not Transport Canada or Euro NCAP at the time of publishing) as a recall.

Tesla mentions that the vehicle’s FSD computer circuit board may short circuit, resulting in the loss of the rearview camera image. The recall itself is focused on the rearview camera - as not having a functional rearview camera breaks a Federal Motor Vehicle Safety Standard. However, it does impact more than just the rearview camera.

As previously mentioned, users have experienced the full loss of Autopilot and FSD on these vehicles, as well as reduced traction control and removal of safety features such as automatic emergency braking, collision avoidance assist, and forward collision warnings. 

While the vehicle remains driveable, it is not necessarily a good idea to drive the vehicle with many of these features, especially with the reduced traction control noted by many people. We’ve already noted that while Tesla has been sending tow trucks to pick up some vehicles, it is also prompting owners to drive the vehicle to their service center in some cases.

Remedy

Unlike most of Tesla’s recalls, this one isn’t entirely an OTA recall, owing to the fact that people have already experienced circuit board shorts and are already waiting for replacements.

The software portion of the recall has already been mostly completed for any vehicles with Tesla software update 2024.45.25.3 or greater. However, a significant portion of the tracked fleet remains on update 2024.44.25.2 (approximately 20%), so we recommend updating your HW4 vehicle whenever you receive the notification.

On the hardware side, Tesla is immediately identifying and replacing hardware that has had circuit board failure. Tesla is also reaching out to customers who have expressed intermittent issues with Autopilot features, active safety features, or vehicle cameras that don't display correctly. If you have experienced any of these issues in a late 2024 vehicle, we recommend submitting a service ticket with Tesla to ensure that your vehicle isn’t affected by this recall.

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