Back in September of last year, Tesla had its Battery Day presentation (full video below). In January of this year, Electrek wrote an article about the Tesla structural battery. So why am I writing about this now? The structural battery pack was just a gleam in Elon Musk’s eye at that time, but soon, there will be cars that incorporate the new design. Here’s what you should think about if you’re considering buying a Model S Plaid or a Cybertruck with the structural battery pack.
As Elon said during the presentation, the structural battery pack was inspired by the airline industry. They used to put gas tanks in the wings of airliners. The tanks added weight. More weight meant more fuel needed to fly. Eventually, the aircraft manufacturers figured out that they could save weight if the wings were the gas tanks. They saved weight that way. It’s the same with battery packs. Right now, there are battery cells that are put together in modules. The modules add weight. Then the modules are put together into a large battery pack. That adds more weight. Then all that stuff is put into the structure. More weight means less range.
Tesla engineers figured out that they could save lots of weight if they eliminated modules and if the battery pack was the structure. They do that by making a honeycomb structure with all the wiring and cooling coils inside it. Then they drop in the 4680 cells and epoxy them to the honeycomb structure. For those of you who are not aware, the designation, 4680 refers to the 46mm diameter of the battery cells and the 80mm height of the Tesla cells. Those battery cells are larger than the ones currently in use by all previously made Teslas so they store more power in each cell. For comparison, visualize the current Tesla battery cells being like AA batteries and the 4680 cells being like D batteries. Remember D batteries?
The following picture is from the article in Electrek cited above. You can appreciate the honeycomb pattern of the pack, a structure known for strength and light weight. The coolant loops are built into the sides of the pack.
So saving weight, stronger cells, less of them. More battery, less other stuff. It’s all good, right? Maybe.
Here’s the bad part.
If the car gets in an accident and the battery pack is breached, you can’t just take out the old pack and drop in another pack. That might not matter because chances are pretty good that an accident bad enough to damage the battery pack will total the car. From an individual’s perspective, that’s why you get insurance. But there are other considerations if you care about the environment you’re leaving to my grandchildren.
Batteries should be recycled. So far, they’re not designed for recycling. With technology at its current state, it’s cheaper to mine new materials than it is to recycle the materials from used batteries. The ability to recycle gets worse when the batteries are epoxied into a big honeycomb structure. I’m not a chemical engineer so I can’t offer any suggestions about how battery cells could be designed to make recycling cheaper than mining new materials, but they should be designed that way.
The other bad thing about the structural battery pack is that cells don’t all deteriorate at the same rate. With the current battery packs, bad cells can be detected and switched out for good cells to rejuvenate the range of an old Tesla. That won’t be feasible with the structural battery pack. That may or may not be important. It depends on whether the cells last as long as the rest of the car or not. Time will tell, but it’s something to think about if you plan to keep your car for the million miles that Tesla claims their cars are designed to last.
Here is Tesla's 'Battery Day' presentation. If you care exclusively about the structural battery, you can jump to the 1 hour, 19 minute mark.
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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.
Not a Tesla App
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
Not a Tesla App
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.
Tesla has officially launched FSD in Mexico. This is the third expansion of FSD since it was first launched in the United States.
The news was shared by Tesla Owners Mexico on X, followed by confirmation from Tesla AI with a simple but exciting message: "¡Hola México!"
FSD features are geo-fenced, meaning that if a vehicle equipped with FSD crosses into a country where the software isn’t supported, it will automatically revert back to Autopilot. This expansion has likely lifted the restriction, meaning the U.S. Tesla owners should now be able to drive into Mexico and continue using FSD without interruption.
FSD Global Expansion Timeline
Tesla has set some lofty goals for itself, announcing in their FSD roadmap that it expects FSD to be ready to roll out internationally in Q1 and expand to right-hand drive markets in Q2. While it’s not clear whether Tesla still expects to meet these targets, this is the latest information that was shared in September 2024:
Q1 2025: FSD is expected to launch in Europe and China, pending regulatory approval.
Q2 2025: FSD rollout for right-hand drive (RHD) markets, with a flexible timeline based on approval processes.
Tesla has faced regulatory hurdles, particularly in China, where FSD testing was recently put on hold. One major hurdle is China’s strict data regulations, which require all training data to be collected and stored within the country. This means Tesla cannot rely on its existing U.S.-based data centers and must build local infrastructure to comply with government policies that prevent vehicle data from leaving China.
Additionally, since FSD relies heavily on fleet data, Tesla won’t be able to leverage its vast global dataset. Instead, the company will need to retrain its AI models using data exclusively gathered from vehicles operating within China. These constraints add complexity to Tesla’s FSD rollout, potentially delaying its expansion in the region.
After initially launching FSD Beta in the U.S. to a small group of influencers, Tesla expanded access to more users through its Safety Score program in late 2021. At first, only those with a perfect score of 100 were eligible, but as FSD improved and Tesla grew more confident in its performance, the requirement was gradually lowered.
In March 2022, Tesla took its first step beyond the U.S. by introducing FSD in Canada with the release of v10.11.1. Since then, Tesla has expanded FSD to Puerto Rico, and now, the launch in Mexico marks another major expansion of the software.
This news will likely raise excitement among users outside of North America who have been waiting for FSD for years. With regulatory hurdles in China presenting unique challenges, Tesla may shift its focus to expanding FSD in Europe and Oceania first.
Meanwhile, Tesla also focuses on launching its Robotaxi network, set to debut in Austin, Texas, in June. The upcoming Cybercabs in Austin could be running early builds of FSD v14 or a specialized version designed for Unsupervised FSD.
Like so many other things happening at Tesla right now, it’s an exciting time as Tesla prepares Unsupervised FSD for the Cybercab, continues the expansion of FSD, and works out all the details of its robotaxi network, such as the cleaning hubs and wirelessly charging capabilities.
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