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Digital Wind Tunnel Tech Behind Tesla Model S Aerodynamics

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The sleek front end design of the Tesla Model S makes it one of the most aerodynamic cars in its class. With a drag coefficient of Cd=0.24, a measure of air resistance over the surface area of the vehicle’s body panels, the Model S is primed for amazing aerodynamic performance due to its low disruption of air flow around the vehicle. This is important on many levels especially in terms of its impact on range. Conservation of energy and efficient use of battery energy equates to more vehicle range.

So, how did Tesla engineers do this? Well, I came across a video from Exa Corporation (makers of the PowerFLOW software that handles predictive analysis of complex flow) which showcases the characteristics of airflow over the body of the Model S.

What intrigued me about the video is the fact that the engineers behind Tesla Motors used virtual technology, a digital wind tunnel if you will, as a way to quickly iterate through designs before embarking on the more traditional approach of clay sculpting and wind tunnel testing.

Rob Palin, Lead Aerodynamicist at Tesla Motors said, “We used Exa’s PowerFLOW transient solver that directly resolves very large eddies to deliver superior accuracy compared to conventional CFD codes,”according to SAE International. “This approach is especially beneficial in areas where flow physics are complex such as in the rear of a curved vehicle. The result is a full-size electric sedan with a drag coefficient of 0.24.”

Taking a look at the video, you can see the large disruption of airflow particularly around the rear-view mirrors.

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Mirrors and wheels can account for as much as a 25% increase in aerodynamic drag

According to Tesla rear-view mirrors are said to increase aerodynamic drag between 3 to 6 percent. Palin goes on to say that wheels can generate an additional 20% of drag as seen in the following flow field diagram from Exa’s PowerFLOW software.

Tesla-Model-S-Aerodynamic-Drag-Wheels

Areas marked in red indicate the highest areas of drag. (Image credit: SAE.org)

“One of the objectives with the Model S was to minimize the airflow around the front wheels and to line up the airflow so it hits the front wheels head on. We needed to avoid air hitting at an angle, as often the side of the tire acts like a bucket that catches the air, producing significant drag. This was an area where we made a huge improvement from the initial concept designs to the final design.”, said Palin.

It isn’t just the brutal neck-snapping, Hellcat smashing acceleration of the the Model S that makes it one of the quickest and most efficient cars in the world, it’s the amazing science and engineering that goes into every detail of this amazing spaceship.

Source: SAE.org

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Tesla Model 3 filings in China show interesting hardware addition

The addition of a front bumper camera to the Tesla Model 3 is a big upgrade from a hardware perspective.

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Credit: Tesla Newswire via China's MIIT

Tesla Model 3 filings in China are showing the vehicle could get a very interesting hardware addition, one that was not included on the “Highland” update when it rolled out to customers a year and a half ago.

The Model 3 Highland is Tesla’s updated version of the all-electric sedan, and was launched across the world in early 2024. It featured a variety of updates, including new exterior and interior designs.

However, there were a few things missing from the update that surprised Tesla fans because they were included on other cars.

One of them was the lack of a front bumper camera, a hardware piece that was included on other vehicles within the company’s lineup, including the Model Y Juniper, an updated version of the all-electric crossover that launched earlier this year.

Now, it seems Tesla is preparing to implement that front camera on the Model 3, as new filings with China’s Ministry of Industry and Information Technology (MIIT) showed the car with the addition:

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The front bumper camera is a small but powerful addition to Tesla vehicles. It not only enhances visibility for simple tasks like parking, helping avoid things like curbs, but it also helps provide a wider field of view directly in front of the car.

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It is also a crucial part of the Full Self-Driving and Autopilot suites, helping provide yet another angle of vision for the vehicle as Tesla makes its suite more robust. It is already improving through software upgrades and data collection, but it could always use additional hardware to enhance accuracy.

A Model 3 Highland test mule was spotted near Boston, Massachusetts, back in May with a variety of additional cameras equipped. Some believed this was a vehicle that was assisting with collecting training data.

Tesla is testing a Model 3 with some mysterious cameras in the U.S.

However, it could be a sign of Tesla planning to add this piece of hardware to a slightly updated version of the new Model 3 that could come to production in various markets in the near future.

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Tesla CEO Elon Musk details massive FSD update set for September release

“This will substantially reduce the need for driver attention, but some complex intersections, heavy weather or unusual events will still require attention.”

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Credit: Tesla Asia | X

Tesla CEO Elon Musk detailed the changes that are expected to come with a massive Full Self-Driving (FSD) update, which is set to roll out sometime in September, he revealed earlier this week.

Tesla has been refining its FSD suite for years, but it has never been as good as it is now. The focus is to get the suite to a point where interventions are no longer needed and drivers simply become passengers, as they will not be responsible for paying attention to the road.

Elon Musk teases crazy new Tesla FSD model: here’s when it’s coming

That version of FSD will come eventually, but not next month. However, there are dramatic improvements that will come with next month’s FSD update that will roll out to the public, Musk said:

“The FSD software update next month will be a major step-change improvement for rare conditions.”

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Additionally, he provided specific details on what would change, hinting that the need for a driver to pay attention will be “substantially reduced,” but there are some “complex intersections, heavy weather, or unusual events” that will still require drivers to assume responsibility for the car:

“This will substantially reduce the need for driver attention, but some complex intersections, heavy weather or unusual events will still require attention.”

We have been teased about these types of updates before, but usually they involve some kind of mention of FSD being ready for unsupervised driving “by the end of the year.” Musk did not mention that here.

There is also the fact that Tesla has another FSD build in Austin for the Robotaxi suite that is more advanced than what is available to the public. It has performed well, Musk says, making claims that there are times when it feels “eerily human.”

Tesla Q2 2025 vehicle safety report proves FSD makes driving almost 10X safer

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The improvements in FSD capabilities in subsequent releases are usually very evident. As Tesla continues to refine the suite for the public, it gains more confidence and becomes smarter through the collection of data and the use of neural networks.

The only thing left to wait for is the release itself, and we are hopeful it will roll out to the public in September, as Musk says.

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Tesla Model Y L’s impressive specs surface in China’s recent MIIT filing

The Tesla Model Y L is expected to launch later this year.

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Credit: Tesla

The specs of the upcoming Tesla Model Y L has appeared in new Chinese regulatory filings, revealing key specifications including a six-seat layout and an extended range of up to 751 kilometers. The variant is expected to launch later this year alongside a new long-range Model 3 variant rated at 830 kilometers.

The updates were listed on the China Ministry of Industry and Information Technology’s (MIIT) latest batch of new energy vehicle models that are eligible for vehicle purchase tax exemptions.

Model Y L to debut with larger battery, six-seat layout

Listed under the model code TSL6500BEVBA0, the Model Y L will feature dual motors producing 142 kW at the front and 198 kW at the rear. It will be powered by a 465-kilogram 82.0-kWh lithium-ion battery from LG Energy Solution, with a pack energy density of 176 Wh/kg, as noted in a CNEV Post report. The long-range crossover achieves 751 km on the lenient CLTC cycle, making it Tesla’s highest-range Model Y to date in China despite its curb weight of 2,088 kg.

The “L” designation is believed to refer to the vehicle’s larger size and seating configuration, as the new variant is listed with six seats. It builds on Tesla’s strategy to diversify offerings in the Model Y lineup, which currently includes both RWD and AWD five-seat versions.

Model 3+ breaks record with 830 km CLTC range

Alongside the Model Y L, Tesla China also registered a new rear-wheel-drive Model 3, which was designated with the model code TSL7000BEVBR1. The vehicle boasts either 800 or 830 km of range on the CLTC cycle, depending on its trim. This marks the highest range yet for any Tesla vehicle in China.

The variant will use a 448-kilogram, 78.4-kWh LG-supplied battery with an energy density of 175 Wh/kg and a peak motor output of 225 kW. The vehicle’s curb weight is listed at 1,760 kg. The model was previously identified in filings as “Model 3+,” hinting at a possible tier above the existing long-range variant, which tops out at 753 km CLTC.

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