Tesla released FSD V12.5.4.1 with software update 2024.32.10, just a day after launching FSD V12.5.5 in update 2024.32.20. This is good for several reasons, but they’ve also included improvements for Actually Smart Summon, which Tesla mentions in the release notes.
This build was released to early access testers last night and will likely roll out wider within the week.
Update 2024.32
First, non-FSD builds have been on 2024.32 for quite a while now, and it looks like this will be the big branch merge to bring FSD V12.5.4 (and V12.5.5) to the latest feature branch. Once 2024.32.10 begins to roll out en masse, owners in North America will soon be able to subscribe to FSD and get the latest FSD version.
Update: This is now rolling out this update to users who have bought Enhanced Autopilot as well, and not just vehicles with FSD. This is the first step to expanding Actually Smart Summon globally. Summon capabilities are included for vehicles with Enhanced Autopilot or higher. Enhanced Autopilot is still available for purchase in some regions, but hasn’t been available in North America since Tesla lowered the price of FSD.
Actually Smart Summon Changes
The changelog for Actually Smart Summon for this build is short but adds a few items that users had already identified as needing some work. Tesla is pushing these updates out all in short order – all ahead of the upcoming Robotaxi event.
Improved Public/High-Speed Road Aborts: This one is fairly valuable, as Actually Smart Summon does not function on public roads or anything that has a higher speed. On the current build of A.S.S., it will just stop the vehicle before turning onto a public road. We’re hoping to see the vehicle either properly pull over, or turn around as required and continue back into the parking lot.
Improved Blocked Camera Aborts: The next update is improved block camera aborts, which should be similar, except instead of stopping for public roads or high-speed roads, A.S.S. stops when the cameras are covered up. This improvement should reduce false-stops and increase confidence.
Reduced False Positive Collision Mitigation Aborts: Third we’ve got reduced false positive collision mitigation aborts – again – A.S.S. stops if it believes there will be a collision. It has been fairly cautious in the current build, leaving a wide berth between it and any obstacles. Now that Tesla has gotten training data from the many drivers who have been using it since it was released, there will be fewer false positives going forward.
Refined Dumb Summon: We’re not sure what improvements are here, but it looks like there are general improvements to the previous forward/backward Summon version.
Update: We initially uncovered new summon options in FSD 12.5.4, where you could now have the vehicle play a sound when Summon completes or is aborted. We covered the new options as an undocumented change in our release notes, but Tesla has now expanded its functionality.
With update 2024.32.10, Tesla now lets you pick from a custom sound from your USB drive to play when Actually Smart Summon completes. This is in addition to the previous sound clip choices of Applause, Ta Da, Ba-dum Tiss and a random sound. Tesla also added “fart” as one of the sound choices, which was previously only played when Actually Smart Summon was aborted.
For now, FSD users can look forward to getting improvements to Actually Smart Summon and the features in update 2024.32 and non-FSD users can look forward to subscribing to FSD and receiving the latest FSD build in the near future.
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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)
