Tesla AI Day 2021 Event Recap

By Henry Farkas

Tesla AI day was last night and most of the event was an in-depth look at how Tesla is solving FSD and all the problems their solving and methods they're using. It definitely wasn't aimed at at the casual consumer.

Tesla AI Day 2021

There was some interesting video where they showed how the integration of all the cameras could predict where other traffic is located, and do it better than the combination of a few cameras combined with radar. We had to take their word for it that the camera integration did a better job. It did look that way on the computer views. Elon also pointed out that they use the Autopilot software not only to drive the car but to predict where the other cars on the road are likely to be in the next few seconds.

Later in the show, things got more interesting. They brought out a person dressed like a robot who danced around a bit. Elon came out again and showed a plan for a human-shaped Tesla robot. He admitted that the one that had danced around the stage wasn't the actual robot, but said that's what the Tesla robot would look like. The purpose of the robot is to perform chores that humans might find boring, repetitive, or dangerous.

Elon mentioned that Teslas are basically semi-sentient robots on wheels. He said that the human-shaped Tesla bot would come out next year. The robots will be friendly and will be able to navigate a world built for humans. They will be five feet eight inches tall and weigh 125 pounds, The face will be a computer screen. The hands will look like human hands and have five fingers. The Tesla bot will be able to walk at five miles/hour. That's faster than normal human walking speed, but most people can run faster than that.

Elon casually mentioned that most people could run away from it and most likely overpower it. He hoped it wouldn't be necessary, but, he said, “You never know.”

So then, he said that the robots would be able to shop for people, do chores around the house, and do repetitive jobs in the workplace. He admitted that having robots available to do jobs in the workplace would be a problem unless there was a universal basic income. That got a cheer from the audience. So I guess there were lots of Andrew Yang fans in the audience.

Then the question period started. The first question was asked of Musk, did he plan to make any of his software open-source? He said that creating it cost too much to just give it away, but he'd be willing to license it to other car companies.

Another interesting question was about whether audible cues would be incorporated into the FSD computer. Elon admitted that it would be important for a fully autonomous car to hear sirens from emergency vehicles, and he said that if someone was yelling at the car from the outside, a fully autonomous car should be able to understand what was being said. It'll be interesting how Tesla plans to tackle this problem for vehicles without external microphones.

Later, someone asked if FSD would work in other countries. Elon said that they were focusing first on the US, but the point was made that driving is very similar in other countries. Elon mentioned that they use training data from fifty countries and that the prime directive of FSD is, “Don't crash.” And that's true in every country. He says that right now, the car is pretty good at not crashing. Clearly, pretty good is not good enough since the drivers still need to pay attention, but the FSD is programmed to not crash into anything on the highway even if it's something it doesn't recognize like a UFO that just crashed on the highway.

I have to mention, here, an experience I had while FSD was engaged. I was driving along a road at night, and I saw a rock in the middle of the road. It was clear that the car didn't see it, and I had to quickly steer around it because it was too late to stop by the time the rock appeared in my headlights. Now I don't have the beta version of FSD, but it's clear Tesla still has some work to do here.

Later, someone asked what will happen with FSD once hardware 4 gets into production. Elon said that hardware 3 will be able to drive much better than any human driver once the software is finished. He says that hardware 4 will come out with the Cybertruck, and it will be able to drive better than hardware 3, but that doesn't mean that hardware 3 is unable to drive. He pointed out that not every regular human driver is the best driver on the road, but that doesn't mean that the regular driver isn't allowed to drive.

An amusing question got asked about whether the car could be spoofed by a picture. Elon suggested that he doesn't see many paintings of tunnels on rock walls as in Wiley E. Coyote cartoons. He mentioned that he has a T-shirt with a stop sign on the front. He says that if someone flashes a Tesla with such a T-shirt, the car will stop, but that Tesla will soon train edge cases like these and the car will learn what is a real stop sign versus a fake one.

Toward the end, someone asked whether we should worry that AI will have its own priorities that might be different from the priorities of the owners of the artificially intelligent robots. Elon said that right now, we're not anywhere near the kind of self-aware super-intelligent robots that people worry about. A car may be able to drive better than most humans. A robot may be able to do boring, repetitive or dangerous activities. That doesn't mean that cars and robots might rise up and rebel against humans. He's going to program his cars and his robots to be “Unequivocally good.”

Elon's final comment about cars was that eventually, cars will drive themselves just like elevators now drive themselves. You get in an elevator, press a button, and it takes you where you want to go. There aren't elevator operators anymore. Eventually, self-driving cars will be the norm. He says that there will still be a few gasoline cars and cars that need to be driven by a human being, just like now, there are still a few horses. But non-self-driving cars will be rare.

You can view the full Tesla AI Day event below:

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

By Karan Singh
Not a Tesla App

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.

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

By Not a Tesla App Staff
Not a Tesla App

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.

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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