Musk says Tesla's next-gen vehicle will be much more utilitarian
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With all the attention on Cybertruck, Tesla is quietly working on the real game changer. Somewhere in Tesla's research and development is the Model 2, the next-gen, more affordable Tesla. It is the car that Tesla predicts will sell more than all of its other vehicles - combined!
The company has long been known for its futuristic and sleek designs, with the upcoming Model 2 touted as the most affordable and utilitarian offering yet. Yes, utilitarian were the words used by Elon Musk as he reiterated the primary focus for the Model 2 would be simplicity in design, manufacturing efficiency, and affordability.
But how might this vision translate into the actual car design? We have a few ideas using some hints and lessons from the past. For simplicity's sake, we will refer to the next-gen car as the Model 2 in this article.
Teardrop Shape: Aerodynamic Mastery
Aptera's vehicle design next efficiency to another level
Aptera
Arguably the most aerodynamic shape for cars, the teardrop design minimizes drag, which is crucial for electric vehicles where range is paramount. The Model 2 could integrate this shape, focusing on the perfect harmony of form and function.
A vehicle is yet to be produced, but it has shown this design and how Tesla could use it. Aptera knows that in vehicle efficiency, drag coefficients are king. It is a crucial metric denoting aerodynamic resistance: while a Toyota Corolla registers at 0.29 and the Tesla Model 3 impresses with 0.23, the Aptera records 0.13. To put that in perspective, the bottlenose dolphin puts up a 0.1.
The McLaren Speedtail
Bloomberg
When McLaren set out to conceive their swiftest road-going model, it didn't merely optimize the engine; it sculpted the very form of the car itself. The McLaren Speedtail's streamlined silhouette, exemplified by its elongated tail, the omission of conventional side mirrors, and aerodynamic front wheel covers, is a testament to this design philosophy.
Three Wheels: Sneak Peak Lines up with Aptera
Tesla working on a concept car
CBS
An image in the Walter Isaacson books seems to be a mock-up of a Model 2. Take a good look at both the product and the pictures on the wall behind it. It appears to be a three-wheel, tear-shaped vehicle. Aptera also has three wheels. The company says it "leads the pack by having the least "rolling resistance" — the energy needed to keep your tires rolling at a straight and steady pace."
Going to three wheels reduces the touch points and areas where energy can be lost. It could incorporate unconventional headlights or eliminate the traditional trunk. The Aptera's radically efficient design offers a glimpse of such out-of-the-box thinking.
Rethinking Doors and the Frunk: Simplifying Structure
Volkswagen's XL1
TopGear
While a four-door design is conventional, a two-door Model 2 would be simpler and likely cheaper to manufacture. Moreover, since the frunk primarily serves as storage in electric vehicles, Tesla could consider eliminating it altogether. This recalls Volkswagen's audacious 1-litre car concept, which featured gullwing doors and a futuristic design.
But we don't need to go back that far, as again, we can point to Aptera's design. The two-door, two-seater has storage room but certainly not to the same level as a Model 3. Given this Model 2 is going to be a point A to point B car, how much storage space is required?
Aero Wheel Design: Balancing Aesthetics with Efficiency
Tesla's Model 3 aero wheels have already demonstrated the balance between aesthetics and efficiency, offering up to a 3.4% boost in range. The Model 2 could take this further by fully enclosing the wheels or adopting innovative designs similar to the McLaren Speedtail's aerodynamic front wheel covers. It could go even further than that; see the next point.
Fender Skirts: Maximizing Range
A render of the Model S with fender skirts
Road and Track
Historically, fender skirts have shown a marked improvement in fuel efficiency. The original Honda Insight from 1999 achieved a drag coefficient of 0.25 with its covered rear wheels. By re-introducing fender skirts, Tesla could further streamline its impressive aerodynamics, extending the Model 2's range. But, as General Motors pointed out, this could require certain design adjustments, like narrower rear tires, to maintain safety and handling.
Mirrorless Design: Reducing Drag
The original Tesla Cybertruck prototype didn't have mirrors
Tesla
Mirrors add drag, and if Tesla can persuade regulators, a mirrorless design would make the Model 2 even more streamlined. Replacing mirrors with cameras has been around for a while. Still, Tesla could be the one to popularize this in mass-market EVs. The company has already been touting this as a feature for the Cybertruck. However, some jurisdictions require external mirrors. At some point during the evolution of the car, regulators must understand that camera technology is superior to mirrors.
While these speculations are based on current trends and historical data, one thing is certain: Tesla's Model 2 will challenge conventions. As the company delves deeper into achieving unmatched manufacturing efficiency and affordability, the Model 2 will likely carry Tesla's legacy of innovation.
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.
Having the ability to open your trunk hands-free can be incredibly useful when your hands are full, especially in a busy parking lot.
Tesla vehicles now support opening the vehicle’s trunk or frunk completely hands-free — no foot waving required.
What is Hands-Free Frunk and Trunk?
Tesla implemented its hands-free feature by leveraging your phone’s position in relation to the vehicle. When you stand still behind your vehicle, the trunk will automagically open for you.
While this functionality isn’t available on every vehicle, it’s available on every vehicle Tesla manufactures today, including the new Model Y, the Cybertruck and other recent models.
With a compatible device and a supported vehicle, you can now open your Tesla’s trunk hands-free.
How It Works
Tesla’s hands-free feature requires the use of ultrawide-band (UWB) in the vehicle and on your phone. Apple and Samsung have supported ultra-wideband for a number of years and most flagship Android devices also support the low-energy feature.
Ultra-wideband allows another device to precisely detect its relative location. In this case, the vehicle is tracking where the driver’s phone is in relation to the vehicle. Since the vehicle is able to more precisely track the phone’s location, ultra-wideband also improves Tesla’s phone key feature.
Since the vehicle depends on your phone, you’ll need to have your phone on you in order to activate the hands-free feature. Simply stand within 2.5 to 3 feet from the front or rear of your vehicle for the frunk or trunk to open. You’ll then hear a couple of chimes. If you continue to stand still, then your frunk or trunk will open automatically.
The chimes serve as a warning that the trunk will open if you don’t move, which helps reduce accidental openings.
Hands-Free Trunk in Action
The video below shows how Tesla’s hands-free trunk feature works.
Supported Models
Since Tesla uses ultra-wideband to power the hands-free feature, only vehicles with the needed hardware are supported. The list of supported vehicles includes:
2021 Model S and later
2021 Model X and later
2024 Model 3 (Highland) and later
2026 Model Y (Juniper) and later
All Cybertrucks
Supported Phones
Your phone will also need to support UWB. Luckily, most manufacturers have included UWB in their devices for several years.
Apple: All Apple devices since the iPhone 11 have included UWB, except for the iPhone SE (2nd and 3rd generation). The iPhone 16e also has UWB.
Android: Most Android phones - especially flagship devices - already support and use UWB for other uses, but it’s not available on all phones. If you have a Google Pixel 6 or higher, Samsung Fold 2 or higher, Samsung S21+, or other recent Android phone, then your phone already supports ultra wideband.
Which Models Support Hands-Free Frunk
Unfortunately, not every supported model supports the hands-free frunk and trunk feature. The hands-free frunk feature is only supported on the Model S, Model X, and the Cybertruck. In addition, the Cyebrtruck is the only vehicle with a powered frunk, so while the Model S and Model X will unlock the frunk for you, you’ll still need to lift it and close it manually. The Cybertruck will open the frunk for you, much like the trunk on another Tesla.
Which Models Support Hands-Free Trunk
While most supported Tesla vehicles can use the hands-free trunk, it excludes the Cybertruck, which doesn’t have a powered trunk.
Enable Hands-Free Trunk / Frunk
If you plan to use your vehicle’s hands-free trunk feature, you’ll need to enable it in settings, as it’s off by default. Simply open Controls by tapping the vehicle icon in the bottom left corner, then navigate to the Locks section.
Within the Hands-Free section, you’ll find a few options, depending on your model. You’ll be able to choose whether to enable the hands-free frunk or trunk and whether you’d like to disable the feature at home.
Preventing Accidental Opening - Exclude Home
Although the hands-free feature requires you to stay still in front or behind your vehicle for a couple of seconds, it can still be triggered accidentally if you’re working around your garage. To prevent accidental opening of the frunk or trunk, Tesla allows you to disable the feature while your vehicle is parked at home.
Tesla determines your home location by the address that’s set in your vehicle. However, it also adds a buffer, meaning that your hands-free trunk feature will also not work in your driveway or at your neighbor’s home. The exclude home feature is located in the same spot as other hands-free trunk features, Controls > Locks > Hands-Free > Exclude Home.
If you have a recent Tesla that’s supported, go ahead and give the feature a try.
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