Happy Birthday to Tesla’s Model 3. It’s hard to believe that five years ago, just 30 Model 3’s had rolled off the assembly line and been delivered. Now Tesla’s answer to a more affordable vehicle is the best-selling electric vehicle in the world, has been named car of the year, is considered one of the safest vehicles on the planet and has a long waiting list of eager buyers.
It’s a birthday, so we should reminisce about the early days. While this iconic car first appeared on the road in 2017, it was on Elon Musk’s to-do list for over a decade.
Elon Musk talks to Wired Science about the Model 3 in 2006
Years later, as it became more of a reality, the car was given the code name BlueStar. It was to be named the Model E, but Ford had already trademarked the wording. Then Musk turned the E into a 3, but he didn’t want the number; he envisioned 3 lines, similar to the current E in Tesla. But Adidas quashed that, arguing it was too close to that brand’s three stripes. So that’s how the 3 was named.
@awadsayeed Yes. Technically Model 3 or maybe three horizontal bars. Won't be three vertical bars.
The Model 3 was supposed to be the smaller, stripped-down version of the Model S to invite more buyers into Tesla and EVs. However, this more affordable, entry-level Tesla holds its own against luxury sedans and even its big sister, the Model S. Tesla has been rolling out several updates throughout the Model 3’s existence, allowing the vehicles to keep up and even pass the Joneses.
In 2019 the Model 3 received a significant software boost when the beta versions of Navigate on Autopilot and Smart Summon were added. Voice commands, a voice keyboard and new language supports were also implemented along with the popular Camp Mode. Once owners posted photos and videos of comfortable beds in the Model 3 with the backseat down, Tesla had to add climate control and a camp fire to complete the experience.
Tesla introduced Dog Mode in Teslas in 2019. In fact, the manufacturer used a Model 3 to unveil the feature to the world. With the help of a sleepy Husky and an excited German Shepherd, Dog Mode was demonstrated to the world on all of Tesla’s social media channels. This made Tesla a must-have for any dog lover!
Also included with the Model 3 in late 2019 and early 2020 was Sentry Mode. This all-encompassing security system records and notifies the owner if anything is happening around or to the Tesla. It’s arguably the most advanced stock vehicle alarm system on the market.
In 2020 the Tesla Toybox was overhauled and updated in all Model 3s. Emissions, sketchpad and many more favorites were revised and made even more fun. But it wasn’t just the games that have been updated; although plenty of games were added over time, Tesla improved it’s maps and dashcam. Later in the year, the Beta version of Full Self Driving was added to all Teslas, including the Model 3. While FSD is still a work in progress, for the system to be available in even the entry-level Model 3 was a big attraction.
A crowd pleaser is the Boombox. This was another addition in 2020 to all models. With the car in park, the boombox blasts music or sound effects through an external speaker. You can even add your own sounds through a USB drive. Perhaps the Boombox should be used by all Model 3 owners to wish their Tesla a happy 5th Birthday!
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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)
