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Tesla’s Elon Musk details Model Y manufacturing improvements, insight on design

Tesla Model Y outside Fremont seat factory. | Image: Reddit u/backstreetatnight

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Tesla CEO Elon Musk recently revealed improvements the all-electric car maker has made to its production process for the Model Y crossover SUV. In an interview on Ride the Lightning podcast, hosted by Ryan McCaffrey, Musk discussed lessons learned from Tesla’s prior transition from the Model S to the Model X as applicable to the Model Y, as well as decisions made from the vehicle’s outgrowth of the Model 3. He additionally provided some insight on the design decisions behind the Model 3, which also carry over to the Model Y’s design.

Musk and McCaffrey’s discussion about the Model Y production process began with the question, “What are the biggest lessons learned from the Model 3 program that you’re applying to the Model Y?” However, Musk indicated that a more relative learning comparison came from Tesla’s design of the Model X and its departure from the Model S.

“The Model X ended up being a radical departure from the S…with the Model Y, we wanted to avoid the technology bandwagon we had with the X. It should have been easy going from S to X, but instead, it was hell because of so many new technologies…It would be too risky to the company to do that with the Y,” Musk explained.

The Model Y crossover needed to address the flexibility expected of vehicles in its class such as cargo capacity, seating for 6 or 7 people, and more ride height than a sedan. Tesla addressed these features while also keeping in mind the effect on battery range a larger vehicle might have, according to Musk.

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“We tried to make the car as similar to the [Model 3] as possible except in the case where a change was necessary to achieve SUV functionality…[all] while still having a low drag coefficient and not increasing the frontal area too much,” he detailed. Overall, Musk concluded that CdA (automobile drag coefficient) and mass of the Model Y only affect 8-10% of the battery range when compared to the Model 3.

The design of Tesla’s Model Y and lessons learned from Model 3 production also led to some manufacturing improvements for the electric crossover. Musk detailed how the Model Y underbody was switched to aluminum casting instead of stamped steel and aluminum pieces, which greatly simplifies the moving parts involved in making the vehicle.

This change effectively means that initially, using two castings to make the structure will take the process from 70 parts to 4 (castings plus joiners), and once the “big” casting machine comes into operation, the process will have brought the process from 70 parts to 1 (casting only). Using casting over stamping reduces the weight of the Model Y, improves MHB (heat produced), lowers cost due to the smaller number of parts necessary, and significantly drops capital expenditure on robots.

Tesla’s factory in Fremont is largely driven by a robotic manufacturing process. | Image: Tesla

As for the manufacturing location of the Model Y, Musk said the decision was not quite final, but the default place was Tesla’s factory in Fremont, California, with the runner-up being Gigafactory 1 in Sparks, Nevada. Producing the Model Y in Fremont would be the fastest way to bring the crossover SUV into production, according to Musk. “One choice isn’t natural over other,” he said. Freemont is producing the Model 3 and the two vehicles share 75% of their components, but Gigafactory 1’s location has a lower cost of living, meaning an overall better value for Tesla.

The similarities between the Model Y and Model 3 being what they are, Musk also discussed with McCaffrey some of the design decisions that initially went into creating the Model 3. In response to the question, “What’s the toughest design decision you had to make on Model 3?”, the CEO cited two primary factors that went into the midsize sedan’s creation: the touchscreen and the nose design.

Reducing the number of screens from two in the Model S to one in the Model 3 came with some pushback, Musk explained. However, he felt that owners would prefer an open view of the road, and everything needed while driving could be fit onto one screen.

This background brought up community rumors about a heads-up display (HUD) being included in Tesla’s vehicles. On the subject, Musk set the record straight – there was never any plan to include a HUD, nor will one be added in the future. He simply doesn’t like them, and the move to self-driving makes them pointless. “We discussed it, but I’ve tried various heads up displays and found they were annoying,” he said. “We felt the car would increasingly go to self-driving…As things are approaching autonomy, why project things you don’t even care about on the screen?”

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The nose of Tesla’s Model 3, which decidedly does not look like Lord Voldemort. | Image: Tesla

Something that customers do care about, though, is the look of their car. Musk detailed the difficulties in making an attractive design for the Model 3, which wasn’t easy thanks to the lack of a front grill on the vehicle. “You don’t want to have the nose to look like Voldemort…You’ve got to get some character or it does not look good.”

Also mentioned was the decision to reduce the width of the Model 3 to 185 cm over the 195 cm of the Model S to help sell more cars in Japan. The country’s parking machines only accept cars up to 195.4 cm wide, which leaves very little wiggle room in the manufacturing process to meet. The change to 185 cm meant that any Tesla Model 3 could fit in any parking garage in Japan.

The Model Y is set to begin production in 2020, and reservations are currently open on Tesla’s website.

Listen to McCaffrey’s full Ride the Lightning podcast interview here.

Accidental computer geek, fascinated by most history and the multiplanetary future on its way. Quite keen on the democratization of space. | It's pronounced day-sha, but I answer to almost any variation thereof.

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Why SpaceX is finishing another space-internet system that isn’t Starlink

SpaceX launched three final O3b mPower satellites Sunday, finishing a lesser known SES satellite network.

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SpaceX had an 87 minute window opening at 2:49 p.m. Eastern on Sunday to fly a Falcon 9 out of Cape Canaveral carrying the final three satellites for SES’s O3b mPower constellation, a project that has taken more than a decade to finish since Boeing and SES first signed SpaceX on for the work.

Unlike the thousands of Starlink satellites SpaceX has stacked into orbit over the years, O3b mPower flies in a different neighborhood entirely. The three new satellites, tagged F11, F12 and F13, are headed for medium Earth orbit at roughly 5,000 miles up, more than ten times higher than Starlink’s shell around 340 miles but still a small fraction of the 22,000 miles where old school geostationary satellites sit. That middle position is the whole point, because a satellite that far out needs far fewer siblings to blanket the globe than a low orbit constellation does. Essentially, SES only needed 13 satellites total to build a network offering quick, steady service that used to require thousands of spacecraft.

With most people having heard plenty about Starlink and almost nothing about O3b mPower, SES and SpaceX already blend the two networks for some customers. Both SpaceX and SES sell satellite broadband, but they’re aimed at different buyers. Starlink is built for volume, direct to consumers, RVs, homes, small businesses, plus a growing aviation and maritime business. O3b mPower skips consumers entirely and sells enterprise grade connectivity to airlines, cruise lines, offshore energy operators, telecoms needing backhaul, and governments, priced and provisioned more like a dedicated circuit.

A 2023 partnership lets cruise ships combine Starlink’s speed with O3b mPower’s steady capacity depending on what a ship needs at a given moment. Sunday’s completed 13 satellite constellation effectively finishes the medium orbit half of that pairing, years after.

Sunday’s mission was already a something on SpaceX’s manifest well before O3b mPower entered the picture. This flight marked its 29th trip to orbit, a history that includes two crewed Axiom missions, the European Space Agency’s Euclid telescope and 22 separate Starlink batches. SpaceX has landed boosters on the droneship A Shortfall of Gravitas so often that Sunday’s touchdown attempt, if it went as planned, was set to be the 661st successful Falcon booster landing to date.

For a company that pushed the Starlink constellation past 11,000 satellites back in August, almost entirely through bulk launches from California, Sunday’s flight was a reminder that SpaceX’s schedule still has room for someone else’s satellites too. SES gets a finished network built for a narrower set of customers, and Falcon 9 gets one more line on an already long resume.

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Tesla gives the Roadster an official “Go for launch” demonstration date

Tesla teased an October 1 Roadster reveal, reviving years of delayed SpaceX thruster hover promises.

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Concept rendering of a Tesla Roadster with SpaceX Package via Grok
Concept rendering of a Tesla Roadster with SpaceX Package via Grok

Tesla teased an October 1 event date for its next generation Roadster, posting an image on X Saturday that shows the car lit up like it is sitting on a launch pad, with the date “10.01” stamped across the bottom and the caption “Go for launch.” A countdown clock on Tesla’s Roadster order page now points to the same date, which falls on a Thursday. The company has not said where the event will happen or whether it will be streamed at the moment. Stay with us @Teslarati for live updates.


Tesla has since sent formal invitations to reservation holders confirming the event will take place in Waco, Texas, about 90 minutes north of its Austin headquarters, based on a digital ticket shared on X by Sawyer Merritt. Tesla did not name the exact venue, though Waco sits close to SpaceX’s McGregor, Texas, rocket test site, previously reported as the planned location for a Roadster thruster demonstration. The invite sets the reveal for 8:30 p.m. Eastern on October 1, requires RSVPs by midnight on September 16, and limits entry to guests 21 and older. Invitations are non-transferable.

The tease follows nine years of a project defined by unimaginable specs along with slipped dates. Musk first showed the second generation Roadster in November 2017 as a surprise reveal at the end of the Tesla Semi event, promising a 0 to 60 mph time under two seconds, a top speed above 250 mph, 620 miles of range from a 200 kWh battery, and production starting in 2020. At last November’s shareholder meeting, Musk set an April 1 demo date and joked the choice gave him “deniability” if it slipped again, which it did, moving first to late April, then to “a month or so,” then to August.

Tesla Roadster SpaceX Package’s 1.1-second 0-60 mph launch visualized in concept video

Whatever Tesla shows on October 1 is expected to center on the SpaceX developed thruster package Musk has described since 2018. Internally code named A71, a nod to the Lockheed SR-71 Blackbird, the system reportedly uses cold gas thrusters fed by a composite overwrapped pressure vessel, the same tank design SpaceX uses on Falcon 9. Musk has said a thruster equipped Roadster could hit 60 mph in about 1.1 seconds under roughly 2.75 g of launch force, well past the 1.9 second figure quoted for the standard car. That version reportedly will not be street legal and has reportedly been discussed as a limited run sold through a track only program.

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The standard Roadster is still expected to carry the original $200,000 base price and $250,000 Founders Series tier, both set when Tesla opened $50,000 and $250,000 reservations in 2017. Tesla VP of Vehicle Engineering Lars Moravy has confirmed production will happen at Gigafactory Texas, with Musk targeting 2027 or 2028, 12 to 18 months after whatever the company demonstrates next month.

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Tesla plans big safety improvements for Full Self-Driving v15

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Credit: Tesla

Tesla is planning to roll out some pretty significant safety and accident avoidance features with Full Self-Driving version 15, which will be the next major FSD deployment from the company.

Tesla AI lead Ashok Elluswamy used a near-miss this week to preview what the company says is the next leap in Full Self-Driving.

In response to a driver whose car had swerved away from another vehicle pulling out of a parking lot, Elluswamy wrote that he was glad the owner was safe and that “even earlier prediction of hazards, even faster reaction time and overall significantly better safety and collision avoidance” would arrive with FSD v15.

The comment landed as Tesla continues to treat software as the primary safety upgrade path. v15 is described internally as a larger architectural step, with a much bigger neural network and tighter coupling between prediction and control.

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The company has already begun using early v15 software in some robotaxi operations while rolling out safety features such as Automatic Collision Evasion into current customer cars, allowing the driving stack to intervene even when the driver is in manual control.

Tesla is rolling out a new FSD version with a massive safety addition

Tesla’s published telemetry is the backbone of its safety argument. In recent North American Vehicle Safety Report data, vehicles with FSD (Supervised) engaged traveled roughly 5.1 million to 5.7 million miles between major collisions, defined as airbag-deployment events.

Tesla’s estimate of the U.S. average over the same period is about 699,000 miles per comparable crash. That is the comparison Tesla often frames as roughly seven times fewer major collisions.

A tighter comparison uses the same Tesla fleet. Cars driven manually with active safety features such as automatic emergency braking still recorded a major collision about every 2.1 million miles. Against that baseline, FSD’s advantage shrinks to roughly 2.4 to 2.7 times fewer severe crashes, which independent researchers argue is the more apples-to-apples figure.

European data released in 2026 pointed in the same direction: Tesla reported FSD as 3.5 times safer than manual driving in the Netherlands and 4.1 times fewer collisions than manually driven Teslas with active safety across more than 100 million kilometers in five approved countries.

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Those numbers do not settle every debate. NHTSA’s Standing General Order still shows Tesla accounting for the large majority of U.S. Level 2 driver-assist crash reports, in part because the fleet logs far more assisted miles than rivals. Critics also note that Tesla’s “U.S. average” mixes crash definitions and driving mix.

Even so, Tesla’s own same-car comparisons, plus lower rates of automatic emergency braking and harsh maneuvers when FSD is engaged, are the evidence Elluswamy is pointing to when he says v15 will push prediction and collision avoidance further. The claim is not that software already eliminates risk. It is that each major version is meant to widen the gap between the system and an unaided human driver.

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