According to Electrek, Tesla, which famously doesn’t have a public relations department and doesn’t spend money on advertising, is now looking to change its referral program rewards again, removing the reward of a thousand miles of free Supercharging for people who refer new customers.
I had a thousand miles of free Supercharging because I used the referral code of a cousin when I bought my Tesla. I bought it during the pandemic so I wasn’t going anywhere. I went ahead and supercharged a few times just to see what Supercharging was like. Since my free Supercharging miles expired six months after I bought my car, it’s all gone now even though I used only about two hundred miles of free Supercharging.
It’s certainly true that some people got lots of free Supercharging because they had a YouTube channel with Tesla-themed videos so lots of people used their link when they bought their Tesla. Tesla says it has spent twenty-three million dollars in the last quarter alone on free Supercharging rewards. Tesla relies on owners, and YouTubers to do their advertising for them. And that advertising must be working since Tesla seems to be able to sell as many cars as they can make. I’m seeing Teslas everywhere I drive these days.
According to the article in Electrek, they’re going to stop awarding miles to people whose referral code was used. In fact, they’re going to stop using referral codes entirely. That will prevent some people from getting large rewards because their referral code was attached to their YouTube videos. Instead, they’re going to use the Tesla app to link potential Tesla buyers to current owners who are willing to give test drives. If the potential buyer who took a test drive becomes an actual buyer, the person who gave the test drive will get rewarded. The article doesn’t say what, exactly, the reward will be.
So, thinking about this new situation, it seems like Tesla wants to reduce the number of test drives at the Tesla stores. There was a time when Elon Musk wanted to eliminate the stores entirely, but cooler heads convinced him that people want test drives, and test drives lead to sales. It looks to me like he’s trying again to reduce his expenditures for salespersons. So what does that mean for us, the current Tesla owners?
I suspect that everything will depend on the reward. Do I want to spend time giving test drives to strangers in my personal car? Not really, unless the reward is interesting. Let’s face it, 1,000 miles of free Supercharging would cost about forty-two dollars. And, if that was the reward for making a sale, you’d get it only when you actually made a sale. You might need to take three or four people on test drives, maybe more than that, in order to make a sale. Let’s say it’s four test drives per sale. Each test drive would last around a half-hour. So that’s two hours work to earn 1,000 miles of Supercharging, around forty-two dollars, or $21 an hour. That sounds like a lot if you’re an unemployed person, but it’s not much if you’re a person who can afford a Tesla Model 3 or Model Y. It’s peanuts if you’re a person who can afford a Tesla Model S or Model X, and it’s inconsequential if you’re a person who can afford a Tesla Roadster.
And why does Elon Musk want to do this? He wants to sell cars without spending much money on the sales process. Tesla makes great cars, but I don’t think they’re going to sell themselves. I have to hesitate before I tell someone as successful as Elon Musk how to run his business. I’m not as smart as he is. But I suspect that the reward for making a sale will have to be more interesting than a thousand miles of free Supercharging. So far, the reward is unspecified. Stay tuned, though. We should find out more soon.
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.
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