As a continuation of our series on Tesla’s patents, we’re taking a look at how Tesla optimizes the performance of AI - FSD, in this case - in autonomous vehicles and robots. Patent WO2024073115A1 goes over efficiently running complex AI models on specialized hardware.
Before we dive into this article, we recommend reading our article on How FSD Works and our other article on Tesla’s Universal Translator for streamlining FSD deployments. While they’re not necessary, the background knowledge will help you appreciate all the details behind how Tesla does their optimization.
Just like before, we’ll be breaking this down into sections and making them as easily understandable as possible.
AI Subnetworks
FSD isn’t a monolithic entity - it is composed of smaller, specialized sub-networks, each dedicated to a specific aspect or function of autonomous operation. This modular design means that Tesla can work on improving one or all sections through training. When one section is improved, the end-to-end nature of the AI also means that the other sections will learn to adapt to the improvements and, therefore, perform better. It also allows for more efficient processing and adaptability during deployment and initial platform training.
These sub-networks might be responsible for tasks such as:
Recognizing and interpreting traffic signals
Detecting and tracking moving objects including vehicles, pedestrians, cyclists, and more
Maintaining lane position and navigating roads
Generating 3D maps of the surrounding environment
Planning paths and making real-time driving decisions
This division of labor allows FSD to handle the complexities of autonomous driving with greater efficiency and precision
Tailored Compilers
Different hardware components are good at different things - and they also require different types of instructions. CPUs, GPUs, and specialized AI accelerators (NPUs) all have unique architecture and capabilities.
Tesla uses a compiler toolchain to translate FSD into machine code that is specifically tailored to each hardware component. This ensures that instructions are executed optimally on each processor, maximizing performance and efficiency.
Strategic Assignment
To further optimize performance, Tesla employs a system that intelligently assigns each FSD sub-network to the most suitable hardware component. This ensures that computationally demanding tasks are handled by the most powerful processors while simpler tasks are delegated to more efficient units.
This strategic assignment of tasks maximizes the overall efficiency of the system, ensuring that each component operates within its optimal performance range.
Optimized Scheduling
The order in which the hardware executes instructions also plays a crucial role in performance. Tesla's system includes an "execution scheduler" that determines the most efficient sequence of operations, minimizing delays and maximizing real-time responsiveness.
This optimized scheduling ensures that the FSD can react quickly and make informed decisions in dynamic driving situations - or quick-response situations with Optimus - like catching a ball.
While the demo here has been confirmed to be teleoperated, Tesla has said they’re working to let Optimus do this autonomously in the future.
To reduce the computational burden and power consumption of FSD, Tesla employs a technique called "quantization-aware training." This involves training FSD to work with lower-precision numbers, which require less processing power and memory. Essentially - rounding.
This approach allows the AI to operate efficiently without significantly compromising accuracy, striking a balance between performance and resource utilization.
Clock Synchronization
In hardware systems with multiple chips, maintaining precise timing is crucial for accurate and synchronized operation. Tesla's system incorporates mechanisms to synchronize the clocks of all processing units, preventing timing errors and ensuring seamless coordination between different components.
This precise clock synchronization is essential for FSD to make accurate real-time calculations and respond effectively to changing conditions.
Redundancy and Failover
To ensure reliability and safety, Tesla's system supports redundant hardware configurations. This means that if a critical component fails, a backup component can seamlessly take over, preventing disruptions in operation.
This redundancy and failover capability is crucial for maintaining the safety and integrity of autonomous systems, especially when driving. Tesla has built-in both physical and software redundancy to FSD, ensuring that it maintains a minimum standard of safety when operating autonomously.
In Simpler Terms…
Imagine a large company (FSD) with different departments (sub-networks) responsible for specific tasks. Each department has its own specialized tools and equipment (hardware components). Tesla's system acts like an efficient management structure, assigning the right tasks to the right departments, providing them with the appropriate tools, and coordinating their efforts for optimal productivity and performance.
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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.
Having the ability to open your trunk hands-free can be incredibly useful when your hands are full, especially in a busy parking lot.
Tesla vehicles now support opening the vehicle’s trunk or frunk completely hands-free — no foot waving required.
What is Hands-Free Frunk and Trunk?
Tesla implemented its hands-free feature by leveraging your phone’s position in relation to the vehicle. When you stand still behind your vehicle, the trunk will automagically open for you.
While this functionality isn’t available on every vehicle, it’s available on every vehicle Tesla manufactures today, including the new Model Y, the Cybertruck and other recent models.
With a compatible device and a supported vehicle, you can now open your Tesla’s trunk hands-free.
How It Works
Tesla’s hands-free feature requires the use of ultrawide-band (UWB) in the vehicle and on your phone. Apple and Samsung have supported ultra-wideband for a number of years and most flagship Android devices also support the low-energy feature.
Ultra-wideband allows another device to precisely detect its relative location. In this case, the vehicle is tracking where the driver’s phone is in relation to the vehicle. Since the vehicle is able to more precisely track the phone’s location, ultra-wideband also improves Tesla’s phone key feature.
Since the vehicle depends on your phone, you’ll need to have your phone on you in order to activate the hands-free feature. Simply stand within 2.5 to 3 feet from the front or rear of your vehicle for the frunk or trunk to open. You’ll then hear a couple of chimes. If you continue to stand still, then your frunk or trunk will open automatically.
The chimes serve as a warning that the trunk will open if you don’t move, which helps reduce accidental openings.
Hands-Free Trunk in Action
The video below shows how Tesla’s hands-free trunk feature works.
Supported Models
Since Tesla uses ultra-wideband to power the hands-free feature, only vehicles with the needed hardware are supported. The list of supported vehicles includes:
2021 Model S and later
2021 Model X and later
2024 Model 3 (Highland) and later
2026 Model Y (Juniper) and later
All Cybertrucks
Supported Phones
Your phone will also need to support UWB. Luckily, most manufacturers have included UWB in their devices for several years.
Apple: All Apple devices since the iPhone 11 have included UWB, except for the iPhone SE (2nd and 3rd generation). The iPhone 16e also has UWB.
Android: Most Android phones - especially flagship devices - already support and use UWB for other uses, but it’s not available on all phones. If you have a Google Pixel 6 or higher, Samsung Fold 2 or higher, Samsung S21+, or other recent Android phone, then your phone already supports ultra wideband.
Which Models Support Hands-Free Frunk
Unfortunately, not every supported model supports the hands-free frunk and trunk feature. The hands-free frunk feature is only supported on the Model S, Model X, and the Cybertruck. In addition, the Cyebrtruck is the only vehicle with a powered frunk, so while the Model S and Model X will unlock the frunk for you, you’ll still need to lift it and close it manually. The Cybertruck will open the frunk for you, much like the trunk on another Tesla.
Which Models Support Hands-Free Trunk
While most supported Tesla vehicles can use the hands-free trunk, it excludes the Cybertruck, which doesn’t have a powered trunk.
Enable Hands-Free Trunk / Frunk
If you plan to use your vehicle’s hands-free trunk feature, you’ll need to enable it in settings, as it’s off by default. Simply open Controls by tapping the vehicle icon in the bottom left corner, then navigate to the Locks section.
Within the Hands-Free section, you’ll find a few options, depending on your model. You’ll be able to choose whether to enable the hands-free frunk or trunk and whether you’d like to disable the feature at home.
Preventing Accidental Opening - Exclude Home
Although the hands-free feature requires you to stay still in front or behind your vehicle for a couple of seconds, it can still be triggered accidentally if you’re working around your garage. To prevent accidental opening of the frunk or trunk, Tesla allows you to disable the feature while your vehicle is parked at home.
Tesla determines your home location by the address that’s set in your vehicle. However, it also adds a buffer, meaning that your hands-free trunk feature will also not work in your driveway or at your neighbor’s home. The exclude home feature is located in the same spot as other hands-free trunk features, Controls > Locks > Hands-Free > Exclude Home.
If you have a recent Tesla that’s supported, go ahead and give the feature a try.
