Tesla Superchargers in Taiwan with Tesla and CCS connectors
@hsumacher/Twitter
The CCS (Combined Charging System) has become the standard for electric vehicle charging over the last few
years.
When Tesla first debuted the 2012 Model S, the CCS charging connector didn't exist. In fact Tesla developed
its proprietary Tesla connector because there wasn't anything capable of fast DC charging.
Today, the CCS connector supports charging speeds up to 350kW.
Tesla already offers Superchargers with CCS connectors in several regions, but they will now begin adding CCS
connectors to Superchargers in the United States.
Tesla will add the CCS connector in addition to Tesla's own connector. This will give non-Tesla owners access
the extensive charging network, Elon Musk said.
Non-Tesla electric cars have been allowed to charge at select Tesla Supercharger locations in France, the
Netherlands, and Norway since November.
Allowing Superchargers - which account for more than half of all fast chargers in the United States to charge
all electric vehicles would be easier and less expensive for everyone involved, and it would substantially
improve the landscape of the current fast-charging infrastructure.
CCS is the obvious charging standard to go with, given that Tesla, like many other manufacturers, has already
accepted CCS standards in Europe and its Supercharger stations are already equipped with CCS connectors.
Tesla's cars and Supercharger stations in North America use its own proprietary connector, which has rendered
Non-Tesla owners unable to use Tesla's fast-charging infrastructure.
It also prevents Tesla owners from charging at other DC charging stations, unless they spend a considerable
amount of money purchasing a CHAdeMO or CCS adapter.
Speaking at the Financial Times Future of the Car summit, Musk said they will add the connectors even if it
lessens their competitive advantage over other automakers.
“It's a little trickier in the US because we have a different connector than the rest of the industry, but we
will be adding the rest of the industry connectors as an option to Superchargers in the US. We are trying as
best as possible to do the right thing for the advancement of electrification, even if that diminishes our
competitive advantage,” Musk said.
This is comparable to Tesla's approach in Europe when the Model 3 was originally introduced with the CCS
standard. Both Tesla and CCS connectors were installed at new Supercharger stations, and the carmaker also
began retrofitting some existing stations.
Last year, the Taiwan EV Charger Equipment Supplier and Manufacturer Advancement Alliance declared that CCS
should be the country's charging standard, forcing Tesla to retrofit CCS connectors to all
Superchargers.
Tesla upgraded Superchargers with CCS connectors in addition to their proprietary connectors a few months
after the decision.
Tesla's CEO gave no indication of when the company planned to begin installing CCS connectors at stations in
the United States.
Is Your Vehicle Compatible?
The connector the US is using differs slightly from the CCS connector in Europe. In the US it's known as CCS combo 1, or CCS1 for short. This is the connector that Tesla will support in the US and it is not interchangeable with CCS2 that is used in Europe.
Tesla is already selling an adapter to go from CCS1 to Tesla's plug, but it is currently only available in South Korea. Tesla is likely to make this adapter available for sale in the US in the future.
However, your Tesla will need to specifically support the CCS adapter. If your Tesla was built after May 2019, then it likely supports the CCS adapter. If it was before then, then it will need to be retrofitted if you plan to charge using the CCS 1 adapter.
You can check whether your car supports the CCS adapter by going to Controls > Software and tapping Additional Vehicle Information.
You can also find more information about how to check whether your car is supported, the cost of a retrofit, and the cost of the adapter in our CCS adapter article.
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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:
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.
![A Look at the Tesla Cybertruck’s Crumple Zones [VIDEO]](https://www.notateslaapp.com/img/containers/article_images/cybertruck/cybertruck-crash-test.webp/e43ef2433bd6e44ae8db63421604a4fb/cybertruck-crash-test.jpg)
