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An inside look at Tesla’s P100D battery pack: more cells, 102 kWh capacity, backwards compatibility in mind

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New details of Tesla’s mysterious P100D battery pack, which Tesla CTO JB Straubel once described as having notable changes in battery module and pack technology, and a “complete redo on the cooling architecture”, have emerged thanks to Jason Hughes’s latest project.

Hughes posted photos of a dismantled 100 kWh battery pack, which he obtained through the purchase of a salvaged Tesla P100D, that reveal an increase in the number of 18650 lithium-ion cells being packed within each battery module. Hughes also discovered a surprising increase in battery capacity beyond 100 kWh, and what appears to be a replaceable connector that allows Tesla to retrofit older vehicles with the newer battery pack.

More 18650 Battery Cells

As outlined in Hughes’s blog post, Tesla was able to fit more of its cylindrical 18650 lithium-ion battery cells into each of the 16 modules making up the P100D battery pack. It’s worth noting that Tesla has maintained a relatively similar form factor on battery packs produced for Model S and Model X vehicles since their introduction. Regardless of the vehicle’s model version – be it a P85, a 60, 75D, or 90D – the uniform skateboard design of the battery pack allows for ease of production, as Tesla can manufacture a single-style pack that can be installed across its fleet of vehicles. Under that same notion, Tesla has also been able to create ‘unlockable features’ by software limiting vehicle range depending on the option purchased by the customer. In other words, Tesla installs the same battery pack into like-kind vehicles (e.g. Model S 60 uses the same pack as Model S 75).

Tesla P85 battery pack module vs. P100D module [Credit: Jason Hughes via @wk057]

Hughes’s dissection of the P100D battery shows that Tesla leveraged the same design concept by distributing a total of 8,256 battery cells across the 16 modules making up the battery pack, bringing total capacity up to the advertised 100 kWh number. However, and much to Hughes’s surprise – he had previously criticized Tesla for providing less battery capacity than what’s perceived by way of the vehicle’s nameplate – Tesla actually provided 102.4 kWh of capacity on the P100D pack, representing a 2.4% increase over what’s marketed.

Backwards Compatible Design

Tesla has also, seemingly, taken into account the ability to retrofit new battery packs onto older vehicles by using the same high and low-voltage connectors across packs. According to Hughes, “the pack itself has the same high-voltage connection, the same low voltages connectors, and the same cooling connector.” However, Hughes notes that there’s subtle changes on the P100D pack that would require a new part in order for it to be retrofittable onto non-P100D vehicles.

“The [P100D] pack has the newer ring around the high-voltage connector. So, it’s plug-and-play (for the most part, firmware and config changes needed) on the Model X and refreshed Model S, however it would require a different spacer ring on the high voltage connector. Tesla even has a part number for it, so it should be pretty simple to put into any Model S/X.” says Hughes.

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What about that new P100D battery cooling architecture?

Well. It’s not magic. Tesla did improve battery cooling in the new P100D 100 kWh battery pack. And Tesla did provide a redone architecture, but it isn’t one of mythical proportions.

Hughes reveals Tesla’s approach to improve battery pack cooling was to use shorter and thinner cooling loops per battery module, thereby improving the rate of heat dissipation. Unlike most other electric car makers who do not “prime” their vehicle’s batteries through the use of a thermal management system, Tesla pumps fluid through the battery module to regulate the temperature of its battery pack in order to bring them to optimal operating temperatures. By ensuring the lithium-ion cells operate within ideal temperatures, Tesla is able to provide the best performance possible, while ensuring cell longevity.

Tesla P100D battery module cooling loops [Credit: Jason Hughes]

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Tesla UK sales see 14% year-over-year rebound in June: SMMT data

The SMMT stated that Tesla sales grew 14% year-over-year to 7,719 units in June 2025.

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Credit: Tesla

Tesla’s sales in the United Kingdom rose in June, climbing 14% year-over-year to 7,719 units, as per data from the Society of Motor Manufacturers and Traders (SMMT). The spike in the company’s sales coincided with the first deliveries of the updated Model Y last month.

Model Y deliveries support Tesla’s UK recovery

Tesla’s June performance marked one of its strongest months in the UK so far this year, with new Model Y deliveries contributing significantly to the company’s momentum. 

While the SMMT listed Tesla with 7,719 deliveries in June, independent data from New AutoMotive suggested that the electric vehicle maker registered 7,891 units during the month instead. However, year-to-date figures for Tesla remain 2% down compared to 2024, as per a report from Reuters.

While Tesla made a strong showing in June, rivals are also growing. Chinese automaker BYD saw UK sales rise nearly fourfold to 2,498 units, while Ford posted the highest EV growth among major automakers, with a more than fourfold increase in the first half of 2025.

Overall, the UK’s battery electric vehicle (BEV) demand surged 39% to to 47,354 units last month, helping push total new car sales in the UK to 191,316 units, up 6.7% from the same period in 2024.

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EV adoption accelerates, but concerns linger

June marked the best month for UK car sales since 2019, though the SMMT cautioned that growth in the electric vehicle sector remains heavily dependent on discounting and support programs. Still, one in four new vehicle buyers in June chose a battery electric vehicle.

SMMT Chief Executive Mike Hawes noted that despite strong BEV demand, sales levels are still below regulatory targets. “Further growth in sales, and the sector will rely on increased and improved charging facilities to boost mainstream electric vehicle adoption,” Hawes stated.

Also taking effect this week was a new US-UK trade deal, which lowers tariffs on UK car exports to the United States from 27.5% to 10%. The agreement could benefit UK-based EV producers aiming to expand across the country.

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Tesla Model 3 ranks as the safest new car in Europe for 2025, per Euro NCAP tests

Despite being on the market longer than many of its rivals, the Tesla Model 3 continues to set the bar for vehicle safety.

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Credit: Tesla Asia/X

The Tesla Model 3 has been named the safest new car on sale in 2025, according to the latest results from the Euro NCAP. Among 20 newly tested vehicles, the Model 3 emerged at the top of the list, scoring an impressive 359 out of 400 possible points across all major safety categories.

Tesla Model 3’s safety systems

Despite being on the market longer than many of its rivals, the Tesla Model 3 continues to set the bar for vehicle safety. Under Euro NCAP’s stricter 2025 testing protocols, the electric sedan earned 90% for adult occupant protection, 93% for child occupant protection, 89% for pedestrian protection, and 87% for its Safety Assist systems.

The updated Model 3 received particular praise for its advanced driver assistance features, including Tesla’s autonomous emergency braking (AEB) system, which performed well across various test scenarios. Its Intelligent Speed Assistance and child presence detection system were cited as noteworthy features as well, as per a WhatCar report.

Other notable safety features include the Model 3’s pedestrian-friendly pop-up hood and robust crash protection for both front and side collisions. Euro NCAP also highlighted the Model 3’s ability to detect vulnerable road users during complex maneuvers, such as turning across oncoming traffic.

Euro NCAP’s Autopilot caution

While the Model 3’s safety scores were impressive across the board, Euro NCAP did raise concerns about driver expectations of Tesla’s Autopilot system. The organization warned that some owners may overestimate the system’s capabilities, potentially leading to misuse or inattention behind the wheel. Even so, the Model 3 remained the highest-scoring vehicle tested under Euro NCAP’s updated criteria this year.

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The Euro NCAP’s concerns are also quite interesting because Tesla’s Full Self-Driving (FSD) Supervised, which is arguably the company’s most robust safety suite, is not allowed for public rollout in Europe yet. FSD Supervised would allow the Model 3 to navigate inner city streets with only minimal human supervision.

Other top scorers included the Volkswagen ID.7, Polestar 3, and Geely EX5, but none matched the Model 3’s total score or consistency across categories. A total of 14 out of 20 newly tested cars earned five stars, while several models, including the Kia EV3, MG ZS, and Renault 5, fell short of the top rating.

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Why Tesla’s Q3 could be one of its biggest quarters in history

Tesla could stand to benefit from the removal of the $7,500 EV tax credit at the end of Q3.

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(Credit: Tesla)

Tesla has gotten off to a slow start in 2025, as the first half of the year has not been one to remember from a delivery perspective.

However, Q3 could end up being one of the best the company has had in history, with the United States potentially being a major contributor to what might reverse a slow start to the year.

Earlier today, the United States’ House of Representatives officially passed President Trump’s “Big Beautiful Bill,” after it made its way through the Senate earlier this week. The bill will head to President Trump, as he looks to sign it before his July 4 deadline.

The Bill will effectively bring closure to the $7,500 EV tax credit, which will end on September 30, 2025. This means, over the next three months in the United States, those who are looking to buy an EV will have their last chance to take advantage of the credit. EVs will then be, for most people, $7,500 more expensive, in essence.

The tax credit is available to any single filer who makes under $150,000 per year, $225,000 a year to a head of household, and $300,000 to couples filing jointly.

Ending the tax credit was expected with the Trump administration, as his policies have leaned significantly toward reliance on fossil fuels, ending what he calls an “EV mandate.” He has used this phrase several times in disagreements with Tesla CEO Elon Musk.

Nevertheless, those who have been on the fence about buying a Tesla, or any EV, for that matter, will have some decisions to make in the next three months. While all companies will stand to benefit from this time crunch, Tesla could be the true winner because of its sheer volume.

If things are done correctly, meaning if Tesla can also offer incentives like 0% APR, special pricing on leasing or financing, or other advantages (like free Red, White, and Blue for a short period of time in celebration of Independence Day), it could see some real volume in sales this quarter.

Tesla is just a shade under 721,000 deliveries for the year, so it’s on pace for roughly 1.4 million for 2025. This would be a decrease from the 1.8 million cars it delivered in each of the last two years. Traditionally, the second half of the year has produced Tesla’s strongest quarters. Its top three quarters in terms of deliveries are Q4 2024 with 495,570 vehicles, Q4 2023 with 484,507 vehicles, and Q3 2024 with 462,890 vehicles.

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