The Design & Engineering Behind the New Model Y [Video]

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Tesla’s Model Y has held the title of the world’s best-selling vehicle—across all categories—for the past three years. And it takes an absolute masterstroke of engineering and design to make an even better, more popular vehicle.

In a newly released video (posted below), Tesla highlights some of the key upgrades and refinements made to the Model Y. While a previous deep dive explored the engineering details [insert link here], this latest video offers a broader look at the improvements. Let’s take a closer look.

Unique Design of the Model Y

The refreshed Model Y is all about individuality. While every Tesla model stands out in its own way, some are more similar than others. For example, the Model S and Model X share a similar front fascia design but still feel distinct. The previous Model 3 and Model Y, however, were often difficult to differentiate, even for seasoned Tesla owners.

That’s no longer the case. With the refreshed Model 3 and Model Y, the differences are clear enough to make each vehicle instantly recognizable. You’ll easily spot them on the road and distinguish them from their predecessors.

Design

The lightbar is the first thing you’ll notice about the design overhaul. Tesla aimed to give the vehicle a wider, more grounded appearance while also creating more space on the front fascia. This newfound space not only improves the vehicle’s look but also leads to some efficiency gains—more on that later.

The rear lightbar is equally striking. It’s a reflective, full-body design, marking a first in the automotive industry. The light is reflected onto a custom applique, which directs it downward, creating a puddle of red light behind the car. As Franz, Tesla’s Head of Design puts it, it gives the impression of an afterburner.

The reflective rear lightbar.

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Ride Comfort

Tesla has been focused on improving ride comfort, and the refreshed Model Y is a testament to that effort. While the original Model Y had more of a sports car-like handling, which was less ideal for family use, the new suspension design focuses on comfort by reducing impact harshness, all while maintaining Tesla’s signature steering feel and precise handling.

This is paired with in-house designed tires, developed alongside the tire manufacturer, resulting in the most efficient EV tires Tesla has ever used. With lower rolling resistance, improved handling, and reduced road noise, these tires contribute to a smoother, quieter ride.

The addition of acoustic glass across every glass surface in the vehicle, combined with upgraded sealing materials throughout the cabin and body, has led to a 20% reduction in overall vehicle noise. This is a substantial improvement for an already quiet EV.

The new silver-infused acoustic glass also reflects heat much more effectively than the older glass, reducing the strain on the vehicle’s climate system. This allows the fan to run at a lower speed, further reducing cabin noise and improving energy efficiency. Tesla has truly pulled out all the stops to make the refreshed Model Y one of the most comfortable and refined passenger vehicles on the road.

Efficiency and EPA Range

When it comes to efficiency, Tesla has meticulously reevaluated every component and design choice of the original Model Y, all while maintaining the same size and form factor that has made it a favorite for millions worldwide. The result? A 10% improvement in efficiency over the previous Model Y, which translates to more range.

The EPA recently announced the official range for the vehicle of 327 miles, beating Tesla’s estimate of 320 miles. This is an increase of 16 miles over the outgoing AWD Model Y, which had an EPA estimated range of 311 miles.

The front ducts have been widened thanks to changes in the front fascia, allowing for improved airflow over the tires and front brakes. Meanwhile, the new thermoplastic spoiler has been redesigned at the rear to be more aerodynamically efficient, contributing to the overall 10% efficiency boost. These updates improve performance and range.

Utility

The Model Y has become the ubiquitous Sports Utility Vehicle, capable of handling just about anything. In addition to improving its performance and efficiency, Tesla has also improved its practicality. The trunk opening has been enlarged, making it easier to load and unload items.

One standout feature is the power-folding rear seats. With just the push of a button, you can effortlessly fold them down or raise them back up. Additionally, the front seats automatically slide forward to create more space when you need to bring the rear seats down.

Tesla also gave the frunk a thoughtful upgrade. It now includes a new drain plug, and the bottom liner is fully waterproof—an improvement over the previous water-resistant version. This means you can fill the frunk with ice or use Tesla’s upcoming frunk cooler without worry. There’s even talk of more accessories on the horizon, and we can’t wait to see what Tesla has in store for this versatile space.

Safety

Safety has always been a top priority in Tesla’s vehicle design, and the Model Y has consistently earned 5-star crash safety ratings worldwide. It’s expected that the refreshed Model Y will continue this trend, maintaining Tesla's reputation for top-tier safety.

Additionally, the new front bumper camera offers valuable assistance for parking in tight spaces or when navigating off-road. While there’s no official word yet on whether these bumper cameras will be integrated into Full Self-Driving (FSD) or Smart Summon for the refreshed Model Y or Cybertruck, it’s definitely something to watch for in future updates.

Interior

Front and rear infotainment

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Inside the refreshed Model Y, Tesla has fine-tuned every detail to create a more premium feel. This includes the addition of ambient lighting, similar to the refreshed Model 3 and Cybertruck, as well as new materials throughout the cabin to elevate the overall aesthetic.

The redesigned heated and ventilated seats take comfort and support to the next level, which is a significant improvement for those who use the Model Y as their daily commuter. A comfortable seat can make all the difference on long drives.

In the rear, the updated infotainment system can now pair with two Bluetooth headsets specifically for the back screen. This means passengers in the rear can enjoy audio independently of the front, so if your kids want to watch cartoons, you can continue enjoying music or the news without any interruptions.

Tesla also developed new acoustically transparent materials, which are used to conceal some of the 16 speakers and the newly positioned microphones. Placing the microphones closer to the driver and front passenger’s heads improves clarity for voice recognition and phone calls.

Be sure to check out the full video below to see the meticulous design work and thoughtful improvements that went into the refreshed Model Y—it’s definitely worth a watch.

Design & engineering walkthrough of New Model Y pic.twitter.com/2jvMQOXGkM

— Tesla (@Tesla) February 8, 2025

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A Look at the Tesla Cybertruck’s Crumple Zones [VIDEO]

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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:

Here you can see the large single piece casting in action in a… https://t.co/Jk4X5erTcm pic.twitter.com/24Nmb1bmU5

— Wes (@wmorrill3) February 20, 2025

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Tesla Eliminates Front Casting on New Model Y; Improves Rear Casting

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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

— Munro Live (@live_munro) March 11, 2025

New Casting Methods

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.

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